Laser cladding applications and development trends

Transkriptio

1 Laser cladding applications and development trends J. Tuominen, Dr. Tech Tampere University of Technology, Department of Materials Science TUT Kokkola Unit Korpintie 8 (Innogate Innogate) Kokkola Finland jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

2 Presentation outline - Surface engineering - Laser cladding - Methods - Features - Coating and substrate materials - Coating properties - Laser cladding applications - Power generation - Oil and gas - Moulds and tooling - Mining & construction - Combustion engines - Aerospace - Development trends in laser cladding - Hybrid techniques (hot-wire, induction assisted laser cladding) - High deposition rate cladding (>10kW) (powder, wire, strip) - On-site repairs and mobile cladding units - Coaxial wire feeding - Monitoring & real time process control jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

3 Economic impact of wear and corrosion - Maintenance, repair and material costs as well as losses due to plant shutdowns - Corrosion of metals cost directly the U.S. economy 276 and indirectly 552 billion USD per year (1998) - They were 3.1% and 6.0% of the gross national product (GNP) - In UK, Japan, Australia, Kuwait, Germany, Finland, Sweden, India and China annual direct corrosion costs range from 1 to 5 percent of the GNP - Approximately one-third of these costs (= avoidable costs) could be reduced by broader application of corrosionresistant materials - Wear cost the U.S. economy billion USD per year (1980) Sources: NACE International and FHWA Report Corrosion costs and preventive strategies in the United States (2002) Department of Trade and Industry - Wear Resistant Surfaces in Engineering (1986) jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

4 Surface engineering Surface modification, alloying and coating methods, cladding Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

5 Milestones 1960 Ruby laser 1964 CO 2 Nd:YAG 1967 CO 2 Cutting 1969 WC impregnation 1976 laser cladding; wire feeding preplaced powder 1979 laser cladding; 1-step powder feeding 1984 coaxial powder nozzle for circular beam 1998 HPDL 2.5X more efficient than CO 2 in cladding, Induction assisted laser cladding Fraunhofer IWS 1999 Industrial laser cladding in Finland Fortum Service Oy KETEK 1917 Einstein Light Amplification by Stimulated Emission of Radiation 1965 industrial laser materials processing; Hole drilling and spot welding 1974 CO 2 Industrial laser hardening 1977 industrial laser cladding; preplaced powder Caterpillar Tractor Co industrial laser cladding; 1-step powder feeding Rolls-Royce Pratt & Whitney 1988 Stellite cladding with CO 2 laser M. Sc. Thesis LUT, Finland 1992 Hot wire cladding T. U. Clausthal 1999 Nd:YAG laser cladding 2001 HPDL cladding TUT, Finland * * 2008 Hot-wire laser cladding: Process, materials and their properties Dr. Thesis TUT/KETEK, Finland Mid 90 s cw Nd:YAG and HPDL > 1 kw Hybrid cladding techniques * J. Archambeault, L. Dubourg, NRCC, Paper # 1104, ICALEO2005 jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

6 Cladding methods Powder and carrier gas Laser beam Powder and carrier gas Laser beam Shielding gas Clad layer Shielding gas Clad layer Substrate Substrate 2-step: preplaced powder 1-step: off-axis powder 1-step: coaxial powder 1-step: off-axis hot-wire (tandem) 1-step: coaxial cold-wire 1-step: coaxial hot-wire Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

7 Lasers available for cladding and their properties Fiber Nd:YAG CO 2 Disc HPDL Wall-plug efficiency* 30% ~3% (lp) ~10% (FAF) 20-28% 35-45% Wavelength 1.07 m 1.06 m 10.6 m 1.03 m nm Beam guidance Fiber Fiber Mirror Fiber Fiber Footprint 1.2m 2 (20kW) 3.2m 2 (4kW) 5.7m 2 (20kW) 3.9m 2 (16kW) 0.3m 2 (6kW) Footprint (chiller) 1.2m 2 (20kW) 3.1m 2 (4kW) 3.0m 2 (20kW) 2.0m 2 (16kW) 0.4m 2 (6kW) Max. power 30kW 6kW 20kW 16kW 15kW Mobility Yes No No Yes Yes Operating costs Low High Moderate Low Low *External chiller not taken into account jari.tuominen@tut.fi Lasertyöstö ASE-seminar Laserpinnoituspäivät 25-vuotta 2011 juhlaseminaari Lappeenranta Kokkola Tampere

8 Laser cladding: strengths and weaknesses Fusion bond (excellent bond strength) Low dilution (few percentages in monolayer coating) 100% denseness (real corrosion barrier coatings) Low heat input (small distortion, narrow HAZ) Fine-grained structure (high hardness and strength) Extended solid solubility (not restricted by thermodynamic equilibrium) Low microsegregation Negligible dissolution of externally incorporated carbides Flexible tailoring of compositions (gradients, multimaterial structures) Easily automatized Real time process control High capital costs, low wall-plug & process energy efficiencies, high tensile stresses Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

9 Coating and substrate materials Hardfacing alloys (Stellites, Tribaloy, Norem, Nanosteel, Self-fluxing alloys, Nistelle, Nucalloy) Superalloys (Inconel, Hastelloy, Monel, CMSX-4, high-cr NiCr) Tool steels (P20, M4, H13, CPM 10V) Stainless steels (316L, 254SMO, 420, 17-4 PH) Hadfield-steels (12-19%Mn, %C, 0-2.5%Cr ) Titanium alloys (Ti-6Al-4V, Ti6242, Ti grade 2) Copper alloys (CuAl, CuNi, CuSn) Metal matrix composites (WC/W 2 C-NiCrBSi, TiC-Stellite, VC-tool steel, SiC-Al) Solid lubricants (MoS 2, WS 2, CaF 2, graphite) Intermetallics (Cr 13 Ni 5 Si 2, MoSi 2, FeAl, NiTi) Gradient layers (FGM) (metal matrix composites, monolithes) Nanostructured and amorphous alloys, intelligent materials Substrates; Fe-, Ni-, Cu-, Al-, Ti-, Mg-alloys jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

10 Wet corrosion Dilution, micro- and macrosegregation restricted E vs. Ag/AgCl (mv) Corrosion properties equivalent to wrought alloys and better than cast structures Inconel 625 on mild steel Time (h) Corrosion rate (µm/year) Titanium wrought SX-717 laser Laser HVOF Wrought HVOF + Laser PTA HIP E vs. Ag/AgCl (V) St 6 laser In-625 HVOF + laser St 21 laser In-625 wrought 625 LASER 625 PTA 625 WROUGHT 625 HVOF + LASER 625 HVOF 316L WROUGHT Alloy 59 laser St 6 HIP AISI316L wrought In-625 laser (19.4 Fe) In-625 laser (9.4 Fe) In-625 laser (6.0 Fe) In-625 PTA St 21 PTA In-625 HVOF Mart. SS 7.31 LASER PTA WROUGHT HVOF+LASER I HVOF+LASER II HVOF Fe E-10 1.E-09 1.E-08 1.E-07 1.E-06 1.E-05 1.E-04 1.E-03 1.E-02 1.E-01 log I [A/cm 2 ] jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

11 Hot corrosion tests - Low diluted high-cr NiCr and Inconel 625 laser coatings outperformed wrought Nimonic80A - Inconel 625 laser coating superior to wrought Inconel 625 (grain boundary attack, role of Mo and its influence on salt acidity) - Inconel 625 laser coating possessed high stability at 650 C - In high-cr NiCr laser coatings Cr-rich phases were prone to molten salt attack - Low high temperature stability -> amount of Cr-rich phases and their Cr content increased Mean thickness loss ( m) Wrought 0 SX-707 HVOF SX-707 laser SX-717 laser Inconel 625 laser Inconel 625 Inconel 718 Nimonic 80 A 42CrMo4 Specimen 1 Specimen 2 Na 2 SO 4 -V 2 O 5 (50/50 wt.%) at 650 C for 1000h jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

12 Abrasion wear studies - Low-stress 3-body rubber wheel abrasion - Crushed dry quartz sand ( mm) - Abrasive feed rate g/min per specimen - Load 23 N - Surface speed of wheel 1.64 m/s - Testing time 60 min NiCrBSi + Recycled WC (70/30 vol.%) (Ti,Mo)C + Stellite 6 (64/36 vol.%) NiCrBSi + SFTC WC/W 2 C/W (70/30 vol.%) jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

13 Abrasion wear studies - High volume fraction (~75%) sintered and HVOF sprayed cemented carbides outperformed all the laser coatings - High vol. fraction (~64%) of fine (<2 m) (Ti, Mo)C particles in St 6 matrix best laser coating - Harder the matrix, better the wear resistance (decreased fracture toughness!) - Fused spherical WC/W 2 C/W and angular WC/W 2 C outperformed dense-coated WC - Nanosteel and WR6 best monolithic laser coatings - Laser coatings exhibited local differences in wear rates due to overlapping Volume loss (mm 3 ) St 21 T-800 SX St 6 Fe37 St 12 WR 10 St 1 IN-718 AISI316L 12C-WC 70/30 Amperit SHS1377 SHS C-NS Nanosteel SHS1436 Ni-hard bulk Monolithic Fe-based laser coatings C-WC 50/50 Amperit jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola C-Rec WC 70/30 SHS1389 St21-WC 50/50 Amperit C-WC 70/30 WOKA C-WC 70/30 SFTC WR6 St6-CrC 65/35 St21-WC 50/50 Amperit WR6-VC 70/ C42P2-WC 25/75 Amperit C-CrC 70/30 16C-WC 50/50 Amperit Durum FCT WC 50/50 SHS1378 HVOF Laser Cast Sintered Wrought Amdry 5843 (75/25) Amperit (75/25) WC-6Co-8Cr (75/25)

14 Sliding wear studies - Block-on-ring type sliding wear tester - Dry conditions at RT - Ring counterparts 42CrMo4 (30 HRC) and 34CrMo4 (60 HRC) - Low-stress conditions (57 N) - Initial Hertzian stresses ~100 MPa - Surface speed 140 m/min - Block temperature monitored during the test - Wear debris collected under the ring load wear block 42CrMo4 ring Clad layer jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

15 Sliding wear studies - Laser coatings outperformed more heavily diluted and softer PTA coatings - Stellite 6 laser coating was better than HIPped Stellite 6 - Nanosteel was as good as Tribaloy T-800 St 21 PTA Laser hardened St 21 laser St 6 HIP St 6 laser St 6 laser St 1 laser T-400 laser T-800 PTA T-800 laser Nanosteel laser SHS 1389 laser SHS 1378 laser CrMo4 ring Wear block St 6 HIP Scar volume (mm 3 ) jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

16 Sliding wear studies Pin-on-disc type sliding wear tester CETR UMT-2 Dry or lubricated conditions Testing temperature C Humidity 5-95% RH Load cells N and N Revolve disc speed rpm ASTM G99-95a 6.35 mm 69 mm Kokonaismassahäviö (mg) (mg) Stellite 6LC vs. M Stellite 6LC vs. Stellite 6LC Stellite 21 vs. Stellite 21 Stellite 6LC vs. Resistant Stellite 21 vs. M Stellite 21 vs. Resistant Stellite 6LC vs. Stellite 21 RAEX AR500 vs. CuAl Stellite 6 vs. CuAl Resistant vs. Resistant jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

17 X-ray diffraction method Xstress 3000 Residual stress studies E 1 sin 2 d i d d n n jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

18 Applications Wind turbine gear box wheel Stork Gears & Services, the Netherlands Kokkola LCC Oy, Finland SIFCO, Ireland Mangle NedClad, the Netherlands Metallodomi S.A., Greece Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

19 Applications Laser Cladding Services, USA Drill bit Technogenia, France Drilling tool Praxair Surface Technologies, USA Waterwall tube panel Eaton Corp., USA Piston rod for hydraulic cylinder Certified by DNV for offshore applications ERLAS, Germany Mould repair Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

20 Hybrid techniques Technology Centre KETEK Ltd., Kokkola Hot wire cladding equipment 4.4 kw Nd:YAG + MIG/MAG jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

21 Hybrid techniques Without induction With induction Stellite 12 on M238 mould steel (646 x 230 x 196 mm 3 ) Fully closed-loop cladding process J. Tuominen, TUT Stellite 20 on AISI 1045 Ring shape induction coil F. Brückner, Fraunhofer IWS jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

22 Induction assisted laser cladding Variation of the bead width during processing COAXpowerline (4kW laser + 14 kw induction = 8 kg/h) (10kW HPDL + 40 kw induction = 30 kg/h under development) jari.tuominen@tut.fi Laserpinnoituspäivät Kokkola jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

23 Laser cladding with high power levels (HPDL) Fraunhofer IWS, Germany 10 kw HPDL fiber coupled 15 kw induction Coax 11 Off-axis 9.2 kg/h 14.5 kg/h (with induction) Lasertyöstö ASE-seminar Laserpinnoituspäivät 25-vuotta 2011 juhlaseminaari Lappeenranta Kokkola Tampere

24 Laser cladding with high power levels (disc) Fraunhofer ILT, Germany RWTH Aachen, Germany 10 kw Yb:YAG disc (300µm fiber) Coaxial ILT 3-jet nozzle for circular beam Off-axis nozzle for square beam 4.6 kg/h (5.25 kw) Lasertyöstö ASE-seminar Laserpinnoituspäivät 25-vuotta 2011 juhlaseminaari Lappeenranta Kokkola Tampere

25 Laser cladding with high power levels (fiber) ARL Penn State, USA 12 kw fiber laser 1D-scanner (20-30Hz) (water-cooled Cu mirror) Off-axis nozzle Material: Deposition Rate: Travel Speed: Laser Power: Scan Width: Inconel 625 on HY kg/hr 0.5 m/min 10 kw 25 mm Lasertyöstö ASE-seminar Laserpinnoituspäivät 25-vuotta 2011 juhlaseminaari Lappeenranta Kokkola Tampere

26 Beam forming/shaping Fiber & disc lasers; excellent beam quality -> very high power densities In laser cladding NOT very high power densities required ( W/mm 2 ) Laser beam spot needs to be expanded: By defocusing with standard welding optics By oscillating mirrors (scanners) By homogenizing optics (integrating mirrors, group of lenses) Power density (W/mm 2 ) Nd:YAG HPDL CO2 2 Fiber Interaction time (s) Not optimal for cladding! jari.tuominen@tut.fi Lasertyöstö ASE-seminar Laserpinnoituspäivät 25-vuotta 2011 juhlaseminaari Lappeenranta Kokkola Tampere

27 Beam forming/shaping (scanners) Large and homogeneous beam profiles required in cladding Rectangular beam profiles by scanners Based on galvanometrically driven or direct motor driven oscillating water-cooled mirror (spring) Sinus, triangular, square waveforms Power can be adjusted along scanning line Unique custom energy profiles Water cooled mirrors (~30 kw) Lasertyöstö ASE-seminar Laserpinnoituspäivät 25-vuotta 2011 juhlaseminaari Lappeenranta Kokkola Tampere

28 Beam forming/shaping (optics) Availability for high power levels? Circular prism integrators (HighYAG) Facetted integration elements (HighYAG) Integrating mirrors Some requirements: ability to withstand high power levels, long working distance preferred due to back reflection Homogenized rectangular spot Homogenized circular spot Lasertyöstö ASE-seminar Laserpinnoituspäivät 25-vuotta 2011 juhlaseminaari Lappeenranta Kokkola Tampere

29 Laser cladding with high power levels (fiber) St. Petersburg State Polytechnical University Insitute of Laser and Welding Technologies Russian-German Laser Technology Centre 15 kw Yb fiber laser (IPG Photonics) Manufactured by NTO IRE- Polus, Fryazino, Moscow Region, Russia = 1.07 m Delivery fiber Ø = 200 m Fiber length 50 m Riedel PC250 chiller jari.tuominen@tut.fi Lasertyöstö ASE-seminar Laserpinnoituspäivät 25-vuotta 2011 juhlaseminaari Lappeenranta Kokkola Tampere

30 Setup for scanner cladding (powder) Medicoat AG powder feeder Flat nozzle + cyclone 3D motion system for welding head and nozzle + 2D welding table ILV DC-scanner: - Flat mirror, OFHC-Copper, silver coated, Ø = 48 mm Precitec YW50 welding head, f = 400 mm Grit-blasting: Al 2 O 3, grain size 800 m Substrates: S235JR (Fe37B) (100 x 60 x 20 mm 3 ) jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

31 Scanner cladding with 15 kw fiber laser 3.1 mm 15 kw, 750 mm/min Ø = 5 mm f = 295 g/min Scan width 75% Frequency 100 Hz (Triangular) Bead width 19 mm Max. bead height above substrate 3.1 mm Total cross-section 37.2 mm 2 -> 14.1 kg/h Powder catchment efficiency 77% Geometrical dilution: 3.3% Inconel 625 jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

32 Scanner cladding with 15 kw fiber laser 15 kw, 750 mm/min 15 kw, 1000 mm/min, 273 g/min, inter-track advance 10 mm Ø = 5 mm f = 315 g/min Scan width 75% Frequency 100 Hz (Triangular) Inter-track advance 9 mm Coating width 37 mm Max. coating height above substrate 4.2 mm Total cross-section mm 2 -> 15.6 kg/h Powder catchment efficiency 79% Inconel 625 jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

33 Deposition rates kg/h Nd:YAG HPDL CO2 Fiber Disc Cold-strip Hot-wire Hot-wire Induction Hot-wire Induction Laser power (kw) Powder scanner cladding Cold-wire linear traverse cladding jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

34 Cladding efficiency (powder) Cladding efficiency x 10-4 (kg/kj) Powder scanner cladding with 15 kw fiber laser Powder feed rate (g/min) 15kW, 1000mm/min 15kW, 750mm/min 10kW, 500mm/min 6 kw HPDL 6 kw CO2 4 kw Nd:YAG *Efficiency of laser was not taken into account jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

35 Process window for powder scanner cladding Power (kw) <150 >150 (= no inter-run pores) 16 D<10% D>10% No fusion bond 10 8 Inconel 625 on mild steel S/F (m/g) D A c A m A m jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

36 Corrosion studies for scanner clad coatings Mass loss (mg) Titanium Laser Hard-chrome Wrought PTA 625 laser (69) 625 wrought 625 laser (68) 625 PTA 316L wrought 2xhardchrome + 316L laser coating on mild steel xhardchrome on mild steel Coating samples corrosion tested were milled on a Makino A55 CNC milling machine at TUT Immersion in 1% HCl + 6% FeCl 3 solution at 70 C for 72 hours Test recommended by DNV for off-shore applications (wrought, weld overlays) jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

37 Strip laser cladding with high power levels ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

38 Strip cladding with scanner 316L strip (w = 30 mm, t = 0.5 mm) 4.4 kw YAG, YW50 (f = 500 mm), ILV DC-Scanner 4.4 kw, 72 mm/min, strip feed 37 g/min, scan width 40%, frequency 20 Hz, Triangular scan form jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

39 Strip cladding with scanner 316L 420 Duplex Inconel 625 ~0.5m ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

40 On-site repairs and cladding Mobile cladding units transported to the components Cost efficient solution (high value massive components, dissassembly & transportation to nearest cladding job shop causes too long shutdown, is affixed or welded to some complex systems etc.) Applications in oil & gas drilling platforms, paper mills, steel plants, nuclear power plants, shipyards, ships, turbine power stations ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

41 On-site repairs and cladding LaserAge Ltd, Ireland, 2 kw HPDL, 3 linear axes, 1200kg Stork Gears & Services BV, the Netherlands, HPDL+robot Hardchrome Engineering, Australia, HPDL+robot Duroc, Sweden, 4 kw fiber + robot, 2500kg ARL Penn State, USA, Nd:YAG repair cell for Vertical Launch System jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

42 On-site repairs and cladding Fiber-coupled HPDL + robot Fast response time: Mobile laser cladding system can be on-site within a day! Stork Gears & Services BV, the Netherlands Preparations for on-site ship repair jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

43 On-site repairs and cladding Repair of dove tail surfaces Repair of damaged flange grooves NedClad, the Netherlands Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

44 On-site repairs and cladding EU-project DOCKLASER Transportation with flatbed truck Mobile laser equipment for dock-area 100 m length fiber, container length 4.6 m, weight ~3 tons SLV Mecklenburg-Vorpommern GmbH, Rostock, Germany jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

45 On-site repairs and cladding Transportation with trailer Mobile laser equipment for mold and die repair Trumpf PowerWeld, laser cladding with wire CNC motion work table Pulsed Nd:YAG Joining Technologies, CT, USA (2002) Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

46 On-site repairs and cladding 10kW fiber laser + chiller + robot Powder feeder + coaxial nozzle Floor mounted tracks & carrier Positioner + tailstock Laser safety curtain Cladding can take place inside and outside container Transportable Laser Cladding System by J. Hakala, Y. Guo, D. He (TTE-5107 Design of Robot Systems) jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

47 Coaxial wire cladding heads Beam splitted into three parts (HighYAG) and focused to circular spot For cold-wire cladding Cladding trials with 3.5 kw YAG power HighYAG, 3x beam splitting Fraunhofer IWS, Germany (2008) Fully omnidirectional ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

48 Coaxial wire cladding heads Beam splitted into two parts (Arnold) and focused to circular spot For cold and hot-wire and powder cladding Wire heated by induction Arnold, 2x beam splitting Fraunhofer IWS, Germany (2008) Fraunhofer IWS, Germany (2010) ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

49 For cold-wire cladding Coaxial wire cladding heads Brazing trials with 2.3 kw YAG power Precitec KG, Germany (2009) ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

50 For hot-wire cladding Coaxial wire cladding heads Hybrid welding trials with 4 kw YAG power Mitsubishi Heavy Industries, Ltd., Japan (2005) jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

51 Axial symmetric direct diode laser 500W Source: Alahautala, T.; Lassila, E.: A method and a laser device for producing high optical power density. International patent application WO 03/ (27 November 2003)an jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

52 Coaxial wire cladding head tests Rofin diode-pumped Nd-YAG 4.4 kw with HighYAG coaxial laserhead at Fraunhofer IWS Wire feeding equipment: DINSE wire feeder DIX WD 300 Water cooled wire nozzle Coaxial gas shielding Wires: Inconel 625 Ø = 1.0 mm (solid) Stellite 21 Ø = 1.2 mm (flux-cored) jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

53 Coaxial wire cladding head tests 1.6 mm IN-625, 3.5kW, 1500mm/min, 1.9 kg/h, dilution 14.9% IN kw 2000mm/min 1 kg/h dilution 4.2% 0.6mm 0.8mm IN kw 2000mm/min 2.1 kg/h dilution 25.2% IN-625 on mild steel (100x60x20mm 3 ) IN-625 on mild steel (D50mm, L500mm) High process stability High cladding efficiency IN x10-4 kg/kj St x10-4 kg/kj No overheat of nozzle during long-term cladding operation jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

54 Process monitoring & real time process control LOMPOC-Pro + EMAqs-camera (high speed process analysis) Measures melt pool size, temperature Mounted coaxially Melt pool width as function of time Laser power as function of time Meltpool width [mm] Laser power [W] Time [s] Time [s] jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

55 Summary & Outlook Beneficial coating properties based on fusion bond and low dilution Minor heat input, low distortion, narrow HAZ New type of lasers available: disc up to 16kW, fiber up to 30kW HPDL s scaled up to 15kW High deposition rates (up to 16-17kg/h) with 15kW fiber laser + scanner (powder cladding) Deposition rates can be enhanced further with additional heat source Coaxial wire cladding process shows high stability jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

56 References - Brückner, F. et al., Calculation of stresses in two- and three-dimensional structures generated by induction assisted laser cladding,, LIM Diettrich, J. et al., Coaxial laser brazing head, LIM Heckert, S. et al., Laser processing heads for cladding and heat treatment applications, LAM Kessler, B., Tools for high power fiber lasers and their applications, Kokkola Laser Cladding Seminar Martukanitz, R. et al., Deposition technology: Current trends and future direction,, LAM Nowotny, S. et al., Increased productivity of laser surface cladding by simultaneously assisting energy sources,, SMT Overlay Welding: Transportable laser cladding system adapted for hazardous areas, Offshore Magazine 66 (2006) 10 - Tsubota, S. et al., Laser welding system for various 3-D welding Development of coaxial laser welding head, Mitsubishi Heavy Industries,, Ltd., Technical Review 42 (2005) 2 - Witzel, J. et al., Increasing the deposition rate of Inconel 718 for LMD, ICALEO 2010 jari.tuominen@tut.fi Lasertyöstö Laserpinnoituspäivät 25-vuotta juhlaseminaari Lappeenranta Kokkola

57 Thank you for your attention! ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

58 Trilaser Laser processing with high power New type of lasers kw available (disc and fiber lasers) Would it be possible to achieve excellent coating quality with considerably higher productivity? To bring some high power (>30kW) technology to Finland In cooperation with: ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta

59 Fatigue durability of laser clad components Tampere University of Technology, Technology Centre KETEK Ltd., Luleå Technical University and CENTRIA research unit of the Central Ostrobothnia University of Applied Sciences conduct the project related to mechanical fatigue of laser clad components Project is funded by EU s Interreg IV A North program Project duration is 2 years Total budget 455 keur Companies benefiting the project include end users of laser coatings (large diesel engines, power transmission components, hydraulic cylinders, pulp and paper handling equipment) and laser cladding job shops, also for those who want their end products to be qualified and proved by official classification societies Project includes testing under various forms of fatigue (axial, torsional and bending) using exceptionally large forces and FEM modelling Jännitys N/mm y = x R 2 = CrMo4 pinnoitettu E E E E+07 jari.tuominen@tut.fi ASE-seminar Laserpinnoituspäivät 2011 Kokkola Tampere jari.tuominen@tut.fi Lasertyöstö 25-vuotta juhlaseminaari Lappeenranta