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

1. Laser Cladding for
Coating, 3D Printing
and Repair
Company Presentation 2018
©LCV 2018

2. About Laser Cladding Venture

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
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
•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
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
Quality System

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. Wear and corrosion protection
LCV- COAT

10. 10
Laser Cladding

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
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
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
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
UltraClad Qualitative Analysis
UltraClad
Full density
Metallurgical bond
HCC
Not dense
Chemical bond
Thermo-spray
Sintered structure
Mechanical bond

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
START
DISCUSS
REVIEWDESIGN TEST
EVALUATE
END
PRODUCT
Project Based Approach
Different design rules compared to SLM and other AM methods
Collaborative Engineering

18. Repair of complex workpieces
LCV- Repair

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
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. Conclusion

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. 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