One of Australia's premier underground drilling companies discovered their new drilling rig's main drive spindle was incorrectly machined, leaving the bearing journal undersized. Laser cladding was identified as a solution to rebuild the bearing surface that could be completed quickly. The drive spindle was pre-machined, laser clad with SS410L steel, and finished machined in one day, allowing the rig to be mobilized with minimal delay for a fraction of the cost of a replacement part.

1. Laser Cladding & Heat Treatment Services
30/10/2015
LASER CLADDING SERVICES
Laser Cladding of an AISI 4340 Drilling Rig
The Problem:
One of Australia’s premier underground raise
drive spindle, freshly arrived from their North American manufacturing facility
0.08mm undersize on the bearing journal. The drive spindle is m
external spline drive, and runs on a
loads when in operation, as it is the main drive spindle that turns
underground service holes, which can be up to 2 metres in diameter. To get a replacement from their
American factory would be a minimum of 2
$18,000. As the drill rig was being mobilised for a new project, time was of the essence,
into thousands of dollars per day.
The Options:
Due to the urgency of getting the drill rig
to site, a replacement was immediately
ruled out, so the engineers back in North
America investigated what repair methods
could be used, based on what was
available locally. Both hard chrome and
metal spraying were initially thought to be
suitable, but due to the high bearing
loads, the mechanical bond from both of
these methods would have failed in the
early stages of underground operations
causing the bearing to spin and strip off
the coating. When the engineers found
out that there is a laser cladding company
in Perth, they contacted Laser Cladding
Services (LCS) to see what could be done.
The Solution:
Due to the high bearing loads and the substrate being
AISI 4340, the welding engineer at LCS selected SS410L
as the correct weld overlay to use. Prep machining
involved machining off 0.3mm from the outside
diameter of the bearing journal, a 0.5mm thick layer
would then be laser clad over the entire bearing surface
area, leaving 0.2mm for final machining. Prior to
machining, the drive spindle was cleaned of its sprayed
on corrosion inhibitor, fully inspected &
house with a portable digital Coordinate
Machine (CMM) to ensure accuracy when finish
machining , then dye penetrant inspected to ensure
there were no surface cracks in preparation for laser
cladding.
Laser Cladding Services Pty Ltd
Lot 500, Fields
Email: enquiries@lasercladdingservices.com.au
Laser Cladding & Heat Treatment Services
LASER CLADDING SERVICES
Laser Cladding of an AISI 4340 Drilling Rig Main Drive Spindle
One of Australia’s premier underground raise-bore drilling companies discovered that their brand new
ly arrived from their North American manufacturing facility, had been incorrectly machined
journal. The drive spindle is manufactured from AISI 4340,
and runs on a 280mm ID bearing. The bearing is subject to extremely high axial & radial
loads when in operation, as it is the main drive spindle that turns the drill rods when boring large diameter
underground service holes, which can be up to 2 metres in diameter. To get a replacement from their
American factory would be a minimum of 2 - 3 weeks, including air-freight, with the total cost adding up to
,000. As the drill rig was being mobilised for a new project, time was of the essence, any
Due to the urgency of getting the drill rig
to site, a replacement was immediately
the engineers back in North
repair methods
available locally. Both hard chrome and
re initially thought to be
suitable, but due to the high bearing
loads, the mechanical bond from both of
these methods would have failed in the
early stages of underground operations,
causing the bearing to spin and strip off
s found
out that there is a laser cladding company
in Perth, they contacted Laser Cladding
Services (LCS) to see what could be done.
and the substrate being
AISI 4340, the welding engineer at LCS selected SS410L
Prep machining
machining off 0.3mm from the outside
0.5mm thick layer
the entire bearing surface
area, leaving 0.2mm for final machining. Prior to
cleaned of its sprayed –
inspected & measured in-
oordinate Measuring
to ensure accuracy when finish
dye penetrant inspected to ensure
in preparation for laser
AISI 4340 Drilling Rig main Drive Spindle as received
undersize bearing journal
Drive Spindle being prep-machined 0.3mm undersize
on the bearing journal
Laser Cladding Services Pty Ltd
ABN 71 154 848 227
ACN 154 848 227
Lot 500, Fields Street, Pinjarra, WA 6208
enquiries@lasercladdingservices.com.au
Page 1
Drive Spindle
bore drilling companies discovered that their brand new main
, had been incorrectly machined
anufactured from AISI 4340, has an internal &
The bearing is subject to extremely high axial & radial
the drill rods when boring large diameter
underground service holes, which can be up to 2 metres in diameter. To get a replacement from their North
total cost adding up to
any delays would run
AISI 4340 Drilling Rig main Drive Spindle as received with
undersize bearing journal
machined 0.3mm undersize
on the bearing journal

2. Laser Cladding & Heat Treatment Services
30/10/2015
The Result:
The Drive Spindle was prep-machined, laser clad,
same day, which allowed the drilling rig to be fully assembled
the repair bill coming in at approximately 9% of a replacement spindle
client.
For more information please visit Laser Cladding
Drive Spindle set up to be Laser Clad
Completed Laser Clad AISI 4340 Drive Spindle prior
to finish machining
Laser Cladding Services Pty Ltd
Lot 500, Fields
Email: enquiries@lasercladdingservices.com.au
Laser Cladding & Heat Treatment Services
machined, laser clad, finished machined and re-dimensionally che
same day, which allowed the drilling rig to be fully assembled and mobilised to site with minimal delay. With
the repair bill coming in at approximately 9% of a replacement spindle, it was a successful outcome for the
please visit Laser Cladding Services at www.lasercladdingservices.com.au
Spindle set up to be Laser Clad Laser Cladding Drive Spindle with SS410L
Completed Laser Clad AISI 4340 Drive Spindle prior
to finish machining
Drilling Rig main Drive Spindle ready to be returned
to the customer
Laser Cladding Services Pty Ltd
ABN 71 154 848 227
ACN 154 848 227
Lot 500, Fields Street, Pinjarra, WA 6208
enquiries@lasercladdingservices.com.au
Page 2
dimensionally checked all in the
with minimal delay. With
, it was a successful outcome for the
www.lasercladdingservices.com.au
Laser Cladding Drive Spindle with SS410L
Drilling Rig main Drive Spindle ready to be returned
to the customer