High-Power Laser Materials Processing

By Eckhard Beyer and Achim Mahrle

The high power laser market has been remarkably influenced by the introduction of high-brightness lasers, i.e., laser sources offering a high optical output power in combination with a high beam quality or a low beam parameter product, respectively. These features are primarily exhibited by fiber and disk laser systems, but diode lasers are also increasingly available with improved beam quality and higher output levels. The development of new processes that make use of the advantages of high-brightness lasers was intensively pursued in recent years and some examples of innovative solutions were given in this paper.

On the other hand, the advent of high-brightness lasers also gave rise to some technical challenges, which still need a reliable solution. One point concerns the optical feedback due to back reflections during processing highly reflective materials. Another serious and often discussed topic, is the occurrence of unacceptable focus shifts when working with high-intensity laser beams. Continue reading

Portable Laser Cladding for the Navy

By E.W. Reutzel, T.A. Palmer, R.P. Martukanitz

Pennsylvania State University’s Applied Research Laboratory has been developing laser-based weld repair techniques for the U.S. Navy for 25 years.  Until recently, the repairs have all been realized in a shop environment, where accessibility is rarely an issue, and where the work space can be carefully controlled in order to realize a laser-safe operating environment.  Laser-based weld repair offers several advantages over conventional techniques: Continue reading

High Deposition Rate Laser Cladding – Recent Advancements

By Jari Tuominen, Jonne Näkki, Henri Pajukoski, Tuomo Peltola, Petri Vuoristo

Laser cladding is currently done with 3-6 kW gas and solid state lasers. Components to be clad or repaired are usually small or some discrete regions in larger components. Net deposition rates are typically 1-2 kg/h. In large area coating applications, conventional coating methods such as thermal spraying (HVOF, HVAF) and overlay welding (SAW) prevail due to higher cost efficiency based mainly on high productivity and low capital costs. For applications such as boiler tube panels in power generation and massive hydraulics in off-shore and mining industries, coating properties produced by conventional coating methods are often insufficient. Continue reading

New Industrial Systems & Concepts for Highest Laser Cladding Efficiency

By: Eckhard Beyer

Fraunhofer IWS

Over the past decade laser buildup welding transitioned from mostly specialized laboratory efforts into an established industrial technology for high quality and precise surface coating deposition. Compared to traditional plasma powder buildup welding processes, laser cladding generates superior corrosion and wear protective coatings. The laser process can also generate localized surface functionalities. These combined traits of the process ultimately led to the industrial breakthrough of the technology. Today there are no acceptable alternatives to laser cladding for many applications including mining, oil and gas production and tool and die making. Continue reading

New Stainless Powders for Laser Cladding

By: Ingrid Hauer

North American Hoganas

New investments into laser cladding as well as wear and corrosion testing equipment have lead to the expanded use of stainless steels. Latest developments show these lower cost alloys are able to yield comparable physical properties to many of the traditional Ni-based and Co-based alloys commonly used today. Continue reading