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Slotevent ‘Verbinden van ongelijksoortige materialen’ - Lcv lasercladding for coating, printing and repair

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Quantitative, qualitative and applied aspects of laser cladding: state-of-the-art, features and typical cases (Jan Lambrecht, Laser Cladding Venture)

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Slotevent ‘Verbinden van ongelijksoortige materialen’ - Lcv lasercladding for coating, printing and repair

  1. 1. Laser Cladding for Coating, 3D Printing and Repair Company Presentation 2018 ©LCV 2018
  2. 2. About Laser Cladding Venture
  3. 3. 3 LCV Introduction Our Mission: Enable our customers to have better products with LMD manufacturing How we work: Practice excellence in Laser Cladding With a focus on QUALITY and PRODUCTIVITY Metal Powder Ceramic Powder Powder and transport gas Laser Melt pool Shield gas Laser cladding is a high-yield 3D printing process for metallic alloys
  4. 4. 4 HydraClad 50 50µm Chrome alternative HydraClad 100 100µm NiCr alternative HydraClad 275 275µm LC & Ceramic alternative HydraClad 900 900µm Weld overlay alternative 2015 – 70 EUR/DM² 2018 – 8 EUR/DM² Hydraulic Coatings
  5. 5. 5 •Minimal heat input → limited deformation •Metallurgical bond between clad and substrate •Up to ~ 100% density •Fine microstructure formed by rapid solidification -> extra hardness •Variable material composition → functionally graded materials •Possible to build up complex structures on substrate (multi-axis deposition) •Modulation possibilities (high productivity – high accuracy) Laser Cladding Features
  6. 6. 6 LMD Applications Repair Components of high value are often easier to repair than buying a new one. Also potential for mobile applications Coating Superior coatings with full metallic bond Economic alternative for thermospray Replacement technology for hard-chrome AM XXL-3D Printing with alloyed metals; Dimensions x10 : parts up to 3 meters .
  7. 7. 7 Quality System
  8. 8. 8 WPS/PQR LMD = material and shape transformation Certified Parameters Product & Process Qualification Coating Development Project Engineering Pre- Industrialisation Industrialisation coating specification Parameter database WPS on substrate PQR
  9. 9. Wear and corrosion protection LCV- COAT
  10. 10. 10 Laser Cladding
  11. 11. 11 Coating Products LCV-CorroSlide (mm) LCV-UltraClad (µm) Layer Thickness 2,5 2 1,5 1 450 270 150 CorroSlide UltraClad
  12. 12. 12 Weld-Overlay Type Material Hardness HRC Ductility Corrosion Process Temp (°C) CorroSlide 304L 21 ++++ ++ 420 CorroSlide 316L 22 ++++ ++ 530 CorroSlide 431L 52 ++ +++ 530 CorroSlide 17-4 PH 35-40 +++ +++ 316 CorroSlide & UltaClad Inconel 625 36 ++++ ++++ 900 CorroSlide NiCrBSi 40 +++ +++ 600 CorroSlide Hasteloy C22 52 + ++++ 550 CorroSlide Ti 6Al4Va 36 + ++ 500 Fully Dense Coatings for corrosion protection
  13. 13. 13 Hard-Facing Type Material Hardness HRC Ductility Corrosion Process Temp (°C) CorroSlide Stelite 6 45-52 ++ +++ 800 CorroSlide Stelite 21 40 +++ +++ 800 CorroSlide 316L + TCC 52-60 ++++ ++ 530 CorroSlide & UltaClad Inconel 625 + TCC 52-62 ++++ ++++ 900 CorroSlide NiCrBSi + TCC 40 +++ +++ 600 CorroSlide Co+TCC 60-68 - +++ 800 CorroSlide H11 50 + - 400 CorroSlide H13 50 + - 400 CorroSlide M2 60 - - 400 Optimized microstructure for wear protection Ni TCC CorroSlide 1MM 8X Lifetime increase compared to Nitriding 3X Lifetime increase compared to MIG
  14. 14. 14 CorroSlide Qualitative Analysis 39 52 Conventional LCV STELLITE 6 HARDNESS HRC 29,7 35 15,7 14,67 3,5 5,62 3,6 4,77 1,16 1,34 2,25 3,1 Wearcoating(mm³/Nm)* 10-6 TCC (vol %) Wear Inconel 625 coating CorroSlide Fine microstructure Minimal TCC dispersion MIG Coarse microstructure Dispersed carbides
  15. 15. 15 UltraClad Qualitative Analysis UltraClad Full density Metallurgical bond HCC Not dense Chemical bond Thermo-spray Sintered structure Mechanical bond
  16. 16. 16 Quantitative Analysis 100% 100% 100% 74% 81% 86% 55% 54% 58% 316L Stelite 6 Inconel 625 TCC CorroSlide cost comparison (normalized on 3 MM MIG reference) ACT MIG ACT CorroSlide ECT CorroSlide 0% 100% 200% 300% 400% 500% Thermo-Spray UltraClad 450 Nicklel Chrome UltraClad 250 UltraClad 150 Hard Chrome UltraClad cost comparison (normalized on 50µ HCC) Source; LCV White Paper on Quantitative Analysis of Laser Cladded Coatings
  17. 17. 17 START DISCUSS REVIEWDESIGN TEST EVALUATE END PRODUCT Project Based Approach Different design rules compared to SLM and other AM methods Collaborative Engineering
  18. 18. Repair of complex workpieces LCV- Repair
  19. 19. 19 Extrusion Screws Repair and increase of lifetime Chemical Valve Repair for reducing delivery time Compressor Shaft Fretting wear: Repair and increase of lifetime Mold Repair of mold LCV-RepairRepairing components Repair via Coating or 3D Printing
  20. 20. 20 Compressor ShaftRepairing components + local + no deformation + no influence in core of shaft + no cracks + good bonding + Conic couplicg : fretting wear + 3,7M – 1 ton + Martensitic stainless steel AISI 410 / DIN 1.4006 / X12Cr13
  21. 21. Conclusion
  22. 22. 22 Good mix of capabilities → Technology with potential for repair, coating and 3D printing Certified process→ Quality manufacturing Availabe today → Contact us Conclusion
  23. 23. Thank You Address Laser Cladding Venture nv Nijverheidslaan 1500 3660 Opglabbeek Belgium Phone & E-mail Tel.: 32 89 65 10 22 E-mail: info@lcv.be Website: http://www.lcv.be/ JAN LAMBRECHT CEO Jan.Lambrecht@lcv.be +32 89 65 10 22

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