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Laser Cladding and Thermal Spraying

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LaserBond™ achieves a welded or metallurgical bond with minimal, precisely controlled heat input provided by an optimized laser beam. Temperature sensitive components and materials, such as hardened …

LaserBond™ achieves a welded or metallurgical bond with minimal, precisely controlled heat input provided by an optimized laser beam. Temperature sensitive components and materials, such as hardened shafts, gears etc, can be repaired with minimal risk of distortion or other undesirable heat effects. The metallurgical bond allows LaserBond™ applied layers to be used in high impact, heavily loaded/stressed situations with no risk of spalling or separation of the overlay. The controlled energy minimizes the undesirable thermal decomposition of hard phases such as carbides, resulting in optimum wear resistance. Due to the extremely low dilution with the substrate, high specification materials can be applied in a thin layer with corrosion and wear resistant surfaces as thin as 0.3mm possible. Thick overlays for significant repairs of up to 20mm can also be applied in multiple passes. Heat affected zones are minimized and the stress related cracking inherent in welded or PTA applied hard facing is generally eliminated. Standard LaserBond™ overlay options include Tungsten Carbide, Stainless Steels, Nickel alloys such as Inconel, and Cobalt alloys such as Stellite1. Other materials can be applied on request.
The High Pressure High Velocity Oxy-Fuel process applies coating material at supersonic velocities, resulting in surfaces of the highest possible quality and performance.
HP HVOF coatings are very dense, very well bonded, and free of the oxides and tensile stresses typically found in coatings produced with other thermal spray processes. Consequently, they perform better in most service environments. HP HVOF wear resistant coatings are being adopted globally as an environmentally friendly, and technically superior, alternative to Chrome plating on components such as aircraft landing gear. Surfaces combining resistance to corrosion and wear are also routinely applied by HP HVOF. LaserBond™ approved HP HVOF coatings include Tungsten Carbide, Chrome Carbide, Nickel based alloys (e.g. Inconel 625 and 718), Cobalt alloys such as Stellite1, stainless steels and copper based alloys.
Ajith Ranasinghe | Sales Engineer
LaserBond Ltd
2/57 Anderson Road, Smeaton Grange NSW 2567
| m:+61417618512 | t: +612 4631 4500 | f: +612 4631 4555
ajithr@laserbond.com.au


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  • 1. ® ®
  • 2. LaserBond is a long established, stable, innovative company operating from sites in Ingleburn NSW (formerlyHVOF Australia), and Gladstone, Queensland (formerly Peacheys Engineering), specialising in the manufactureand reclamation of industrial components and assemblies operating across a broad range of industries andenvironments, often for critical applications that require optimised surface properties.LaserBond Ingleburn commenced trading as HVOF Australia in early 1993 with a vision based on dramatically reducing maintenancecosts and extending machinery life by adopting leading edge technologies to meet the ever changing needs of industry. The formationof the company coincided with a significant technology development in thermal spraying known as High Pressure High Velocity OxyFuel (HP HVOF). HP HVOF considerably increased the quality and performance of thermally sprayed coatings and as a consequencegreatly broadened the range of potential coating applications. By initially concentrating on these new applications and supporting theirdevelopment with an extensive in-house metallographic laboratory, the Company quickly established itself as a technical leader in thethermal spray market. In 2001, after significant research, LaserBond commissioned it’s first laser cladding system, to further broaden it’scapabilities, and to provide it’s customers with access to coatings and overlays with a full metallurgical bond. This technology permits thedeposition of precision layers of material, with minimal heat input, and no unfavorable metallurgical side effects.This portfolio of technologies allows LaserBond to reclaim almost any industrial component, often improving its inherent properties, oralternatively to manufacture a new component, incorporating surface enhancing technologies where appropriate.LaserBond Gladstone began life in 1981 as Peacheys Engineering, focused on providing manufacturing and breakdown services to theCentral Queensland region. The continuous growth of the business has broadened the range of services offered to include a full machine(CNC and conventional) shop able to handle large and small quantity production at the highest possible quality and accuracy. In 2008 acustom designed fabrication facility was built to diversify the company’s position, capacity and capability, with the additional space andinfrastructure also increasing the flexibility to take on large scale fabrication, assembly and disassembly work. A complete portfolio ofsurfacing technologies will be added, duplicating the capability that exists in Ingleburn, providing these highly specialised technologies toexisting and new clients in this rapidly growing industrial market.LaserBond today is a publicly traded company (symbol: LBL) after listing on the ASX in late 2007. Aggressive plans for growth in capacityand capability, and expansion into other key market locations, while continuing to evaluate and embrace emerging technologies, will beexecuted by the company’s vastly experienced management team and staff. ®
  • 3. Reclamation and Surface Engineering LaserBond® The LaserBond® process produces deposits with a full metallurgical bond utilising a precisely focused laser beam, providing infinite control of the energy and heat transfer to the base material. Temperature sensitive components and materials, such as hardened shafts, gears etc, can be repaired with minimal risk of distortion or other undesirable heat effects. The typical benefits are The metallurgical bond allows LaserBond® applied layers to be used in lower running costs high impact, heavily loaded/stressed situations with no risk of spalling orminimised down-time and breakdowns separation of the overlay. The infinite controllability of the laser energy reduced waste of high value materials minimises the undesirable thermal decomposition of hard phases such as increased productivity/up time carbides, resulting in optimum wear resistance. reduced spare parts inventory reduced environmental impact Due to the extremely low dilution with the substrate, high specification materials can be applied in a thin layer with corrosion and wear resistant surfaces as thin as 0.3mm possible. Thick overlays for significant repairs of up to 20mm can also be applied in multiple passes. Heat affected zones are minimised and the stress related cracking inherent in welded or PTA applied hard facing is generally eliminated. Standard LaserBond® overlay options include Tungsten Carbide, Stainless Steels, Nickel alloys such as Inconel, and Cobalt alloys such as Stellite1. Other materials can be applied on request. LaserBond can reclaim fatigued and worn industrial parts at a fraction of the cost, and usually in less time, than a replacement can be sourced, while also improving the part’s resistance to wear and corrosion, increasing reliability and service life. New components and replacement parts can also be surface engineered to provide extended service life in a range of challenging environments and applications. Some of the industries we serve include steel making & processing aluminium manufacture and rolling pumps and valves printing and packaging alumina smelting plastic and film manufacturing liquid natural gas processing blades and toolmaking oilfield drilling and exploration glass manufacturing paper making & conversion automotive and motorsport timber and chipboard concrete and building products underground and surface mining aerospace and gas turbines materials screening and handling food production and processing road and rail equipment merchant and defence marine coal fired power generation chrome plate alternatives water and waste water treatment agriculture
  • 4. Thermal SprayingThermal Spraying processes produce high performancesurfaces with a mechanical bond that is maximisedthrough the thorough cleaning and preparation of thesubstrate/component surface. There is absolutely no riskof distortion or metallurgical changes as componenttemperatures are kept low, generally below 200oC.HP HVOFThe High Pressure High Velocity Oxy-Fuel process appliescoating material at supersonic velocities, resulting insurfaces of the highest possible quality and performance.HP HVOF coatings are very dense, very well bonded, andfree of the oxides and tensile stresses typically found incoatings produced with other thermal spray processes.Consequently, they perform better in most serviceenvironments. HP HVOF wear resistant coatings arebeing adopted globally as an environmentally friendly,and technically superior, alternative to Chrome platingon components such as aircraft landing gear. Surfacescombining resistance to corrosion and wear are alsoroutinely applied by HP HVOF.LaserBond approved HP HVOF coatings include TungstenCarbide, Chrome Carbide, Nickel based alloys (e.g. Inconel625 and 718), Cobalt alloys such as Stellite1, stainless steelsand copper based alloys.Plasma SprayPlasma thermal spray is used to apply higher meltingpoint materials such as ceramics/oxides. Applicationsinclude high temperature thermal barrier coatings andwear resistant coatings where thermal and electricalresistance is also desired. LaserBond approved Plasmacoatings include Chrome Oxide, Zirconia, AluminiumOxide and several other ceramic blends.Other Thermal Spray SystemsFor economical dimensional restoration, Arc Wireand Combustion metal spraying systems are used asappropriate to the technical and economic needs ofspecific applications. The most commonly appliedmaterials include stainless and carbon steels, nickelalloys, bronzes, and copper. This technology can also beused to apply coatings for anti-corrosion and tractionapplications.
  • 5. Machine ShopsA comprehensive range of modern, large capacity CNC Lathes, Mills andBorers, in addition to a variety of conventional manual lathes, mills andborers, cylindrical, surface and internal grinders etc are installed in boththe Gladstone and Ingleburn facilities. These are used to manufacturenew components (from one offs to large batches) and parts in a widerange of sizes, weights and geometries. Additionally, this equipment isutilised to restore and reclaim worn and damaged components to precisetolerances and required surface finishes.The company has recently invested in several new pieces of equipment,including a large HNK CNC Borer (X-4000mm, Y-2300mm, Z-2300mm,Payload- 15,000kg) complete with 30 tool automatic changer and CNCfacing head. New Okuma CNC lathes/mills have also been installedto enhance existing CNC turning capacity. These acquisitions equipLaserBond with significant capability, and the capacity to provide thehighest quality work with quick turnarounds to meet the needs ofbreakdowns and shutdowns when necessary.A full capacity and capabilities list is available on our website.Grinding and SuperfinishingUsing semi-automated and manual equipment in conjunction withprecision ceramic and diamond abrasives, we can finish any coatingor component materials to the highest specifications, including mirrorfinishes. Typical applications processed include hydraulic rods andmaterial processing rolls.
  • 6. Fabrication (Qld)In 2008 a large custom designed fabrication facilitywas built to increase our capability and capacity forlarge fabrication projects. The expanded capabilityhas been supported with upgraded welding (MIG, TIGand Stick - GMAW, GTAW & MMAW) equipment, heavyduty positioners and twin 20Tonne overhead cranecapacity.A range of materials can be fabricated including mildand stainless steel, in addition to aluminium alloys. Weare routinely handling projects that include complexshapes and geometries, pipe work, structural steelwork and hardfacing.
  • 7. Major Projects (Qld)LaserBond’s unique combination of expertise, experience and resources,in addition to our client need based focus, makes us ideal for takingon complex projects that may involve some or all of the various corecompetencies offered.Recently completed projects include pipeline fabrication andinstallations, infrastructure and processing upgrades for minerals refiningplants, and the overhaul of core components such as turbines, gearboxes,compressors and pumps to satisfy the needs of client plant shutdownsand breakdowns.Projects are fully supported by our engineering staff with qualityprocedures, supporting documentation and drawings as required tomeet our clients many and varied needs.Fitting and Assembly Services (Qld)As appropriate to the needs of our clients we also offer a completecomponent/system/equipment overhaul service. This is particularlyappropriate where our range of other services allow for a reduction inthe turnaround, maintenance or rebuilding time, or for the trial fitting ofnewly manufactured or reclaimed component parts.Site WorkThe workshops are set up for maximum flexibility to handle a large rangeof component sizes, geometries and weights. However, if your equipmentis too big to economically dismantle and transport, we can bring ourtechnology to site using our trained and qualified operators. We havesuccessfully completed site jobs for a range of industries all over Australia.
  • 8. Metallographic LaboratoryDue to the many and varied applications and materialsthat are processed by the LaserBond workshops, thedecision was taken to establish an in house laboratoryto carry out testing and examination, includingmetallographic characterisation, hardness testing, andchemical analysis.Among the tools required for this work is a ScanningElectron Microscope (SEM) allowing for investigation ofcoatings and metallurgy down to the nano scale. The SEMallows for examination of microstructures and surfacetopography at magnifications up to 200,000 times, alongwith analysis of material chemistry, location or migrationof specific elements within a structure etc.The lab is routinely used for the optimisation of coatingsand overlays, quality control of incoming materials,reports to clients on new applications and materials, andfailure analysis as required. Examination of the effectson substrate metallurgy of the coating or claddingoperation is done routinely to ensure component integrityor properties are not compromised. This facility is aformidable tool, and further differentiates the LaserBondapproach to total customer support.
  • 9. Technology LicensingLaserBond’s business revolves around and exploits a range of nichetechnologies to provide a myriad of optimised solutions to industry’swear problems. These same technologies can be acquired fromLaserBond via tailored equipment and licensing packages whichwould typically include a complete multi-component turnkey system(LaserBond® or HVOF) supported by the necessary know-how, training,installation, and commissioning. The LaserBond option provides openaccess to many years of the exact unique experience and supportrequired to allow for the shortest possible timeline from equipmentpurchase to return on investment.QualityLaserBond is quality certified to ISO 9001:2000 standard (since 2003),proving our commitment to continuous improvement, the quality of ourproducts and services, and the ongoing satisfaction of our Customers.Since our inception, we have gained a strong reputation for supplyingconsistently high quality products and services. As a result our Customerscan expect only the highest quality standards in all business relations.Quality of workmanship has always been, and will continue to be ahallmark of LaserBond.  We welcome customer audits of our QualityManagement System.
  • 10. Occupational Health and SafetyThe occupational health and safety of all personsemployed within the organisation and those visitingthe organisation are considered to be of the utmostimportance. Resources in line with the importanceattached to occupational health and safety will bemade available to comply with all relevant Acts andRegulations and to ensure that the workplace is safeand without risk to health.The promotion and maintenance of occupationalhealth and safety is primarily the responsibility ofManagement. Management at all levels are requiredto contribute to the health and safety of all personsin the workplace. To this end, it is management’sresponsibility to develop, implement and keepunder review, in consultation with its employees, theorganisation’s OHS Program.LaserBond will review its program and policieseach year and at other times if any significant newinformation or legislative or organisational changewarrants a change in those policies.Technology, Leadership and StrengthIn today’s ever shrinking and increasingly competitiveworld, industry must minimise the cost of wearin industrial processes. LaserBond remains at theforefront of developments to assist industry in theseendeavors. Our customers are reaping the benefitsof longer component life, reduced down-time, lowercosts and access to the broadest range of machining,surfacing, and fabricating technologies available froma single company anywhere in Australia.LaserBond stands behind every job carried out,providing a conditional warranty for all manufacturingand reclamation work. Put us to the test. ®
  • 11. ®LaserBond Limited28 York RoadIngleburn NSW 2565 AustraliaLaserBond LimitedPO Box 597Ingleburn NSW 1890 AustraliaTelephone 02 9829 3815International +612 9829 3815Fax 02 9829 2417International +612 9829 2417Email info@laserbond.com.auLaserBond Qld Pty Ltd10 Blain Drive, PO Box 1057Gladstone QLD 4680Fabrication Shop5 George Mamalis PlaceGladstone, QLD 4680Telephone 07 4972 4522International +617 4972 4522Fax 07 4972 5411International +617 4972 5411Email info@laserbond.com.auwww.laserbond.com.au