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Multi‑axis Platform‑type Laser Cladding System
Overview of Laser Cladding Technology
Laser cladding is an advanced metal surface additive‑manufacturing and surface‑strengthening process. High‑energy fiber laser melts both metal powder and the thin surface layer of workpiece substrate. A metallurgically‑bonded high‑performance cladding coating is formed after rapid cooling. It realizes surface reinforcement and dimensional restoration for worn components, improving wear‑resistance, corrosion‑resistance, high‑temperature resistance and anti‑oxidation performance of workpieces. Compared with conventional processes such as electroplating and overlay welding, it features low heat input, minimal substrate deformation and high coating bonding strength with small post‑machining allowance. It serves as an eco‑friendly remanufacturing solution for mining, power, petrochemical, shipbuilding and metallurgy industries for part remanufacturing, mold repair and reinforcement of shaft & roller components.
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Main Equipment Configuration
| Sub‑system | Component Name | Configuration Description |
|---|---|---|
| Laser Generating Unit | Fiber Laser | 3000 W fiber laser; wavelength 1080±10 nm; power adjustment 10‑100%; fiber core diameter 600 μm, fiber length 20 m, LOE interface; stable short‑term and long‑term power output |
| Optical Processing Unit | Laser Cladding Head | Coaxial powder‑feeding cladding head, max. withstand power 4 kW; collimation 100 mm, focal length 250 mm; collimation & focusing adjustment range 0‑20 mm; powder convergence size ≤2.5 mm, LOE fiber interface |
| Powder Feeding Unit | Dual‑hopper Powder Feeder | 220 VAC power supply; applicable powder particle size 20‑200 μm; stepless rotating speed 0‑20 r/min; powder‑feeding repeat accuracy ＜±2%; independent PLC control; nitrogen / argon as carrier & shielding gas |
| Cooling Unit | Industrial Water Chiller | Rated power 2.71 kW; temperature control accuracy ±0.5 °C; water‑tank capacity 16 L; circulating cooling for laser and cladding head |
| Control Unit | Integrated Control System | PLC‑based industrial control for interlocking of laser, powder feeder and gas circuit; signal docking with external multi‑axis motion platform; process‑parameter storage and alarm status monitoring |
| Accessory Kit | Spare‑part Kit | Protective lenses, laser safety goggles, complete gas‑water pipelines and connectors |
Equipment Performance Specifications
| Item | Specification |
|---|---|
| Model | Multi‑axis Platform‑type Laser Cladding System |
| Process | Laser cladding (laser hardening expandable) |
| Rated Laser Output Power | 3000 W |
| Laser Wavelength | 1080±10 nm |
| Motion Mechanism | Interfaced with customer‑existing multi‑axis platform (3‑5‑axis linkage) |
| Powder Feeding Rate | 1‑150 g/min |
| Powder‑feeding Repeat Accuracy | ＜±2% |
| Applicable Powder Granularity | 20‑200 μm |
| Total Power Supply | 380 V three‑phase, 50 Hz, 60 A |
| Cooling Mode | Water circulating cooling |
| Shielding / Carrier Gas | Argon, nitrogen, supply pressure ≥0.5 MPa |
| Max. Endurable Power of Cladding Head | 4 kW |
| Powder Convergence Spot Size | ≤2.5 mm |
| Communication Protocol | EtherCAT / Modbus supported for external motion‑system docking |
| Applicable Powder Materials | Iron‑based, nickel‑based, cobalt‑based, copper‑based alloy powders |
Operation and Maintenance
Operating Specifications
- On‑site Environment Requirements: Place laser unit in independent air‑conditioned room. Stable gas supply with pressure ≥0.5 MPa shall be available at workshop. Laser‑safety barriers and protective goggles shall be equipped for working zone. Reliable equipment earthing shall comply with electrical codes.
- Laser‑safety Regulations: This is a Class‑4 laser device. Never look directly or indirectly into laser beam. Do not disassemble protective assemblies of cladding head during operation. Operators must wear laser‑safety goggles matching the wavelength.
- Powder & Gas Handling: Avoid metal‑powder dust dispersion; wear dust‑proof protective gear during operation. Regularly inspect inert‑gas (argon / nitrogen) pipelines for leakage. Dispose of waste powder as industrial hazardous waste per relevant regulations.
- Startup & Processing Workflow: Power on water chiller first and confirm water temperature within process range. Check gas‑circuit pressure and powder‑feeder material level. Verify communication with external multi‑axis motion platform. Turn on shielding gas before laser emission. Stop laser first upon job completion, keep gas supply for delay period, then power‑off each unit sequentially.
- Process Notes: Perform trial cladding on test coupon before formal production to verify molten‑pool status and powder‑feeding stability. Respond promptly to system alarms; trigger emergency stop under abnormal conditions and troubleshoot before resuming production.
Routine Maintenance
- Optical‑component Maintenance: Never touch protective lens or collimating lens with bare hands. Inspect protective lenses periodically and replace burnt or contaminated ones in time. Cladding‑head lenses and nozzles are consumables; clean powder spatter regularly. Non‑professionals shall not disassemble internal optical parts of cladding head.
- Powder‑feeding System Maintenance: Clean residual powder inside hoppers and pipelines after each batch to prevent caking and blockage caused by moisture. Calibrate rotating speed and powder‑feeding flow periodically to guarantee feeding accuracy.
- Water‑chiller Maintenance: Inspect cooling‑water level and water quality regularly; replace cooling water and clean filters as scheduled. Check water‑circuit joints for leakage to ensure sufficient heat dissipation for laser and cladding head.
- Gas & Electrical System Maintenance: Inspect gas‑pipe joints and solenoid valves for air leakage; check terminals for loose connections. Keep operation logs and alarm records for fault diagnosis.
- Spare‑parts & After‑sales: Stock consumables such as protective lenses, powder‑feeding nozzles and sealing gaskets. Contact manufacturer engineers for failures of control system or laser source; user self‑disassembly is not recommended.
