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LASER CLADDING AS A REPAIR TOOL

R. Persoons1, M. Rombouts1 and D. Robberecht2


1 Laser Centre Flanders, VITO, Mol, Belgium
2 Maintenance Partners Heavy Duty nv , Zwijndrecht, Belgium
VITO
X

Materials Technology

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Confidential – © 2009, VITO NV – All rights reserved
VITO – MATERIALS TECHNOLOGY UNIT

materials processing

laser powder plasma


applications processing technology

measurements and testing

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Confidential – © 2009, VITO NV – All rights reserved
MATERIALS TECHNOLOGY UNIT - LASER GROUP

» Reference centre for laser technology:


Flanders Laser Centre

» Technological advisory service

» Laser demonstration centre

» (Limited) production series

» Laser (hybrid) welding

» Laser surface treatments

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Confidential – © 2009, VITO NV – All rights reserved
Outline

» Activities of VITO

» Introduction in laser surface treatment

» Case study 1: Repair of compressor shaft

» Case study 2: Repair of compressor wheel

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LASER SURFACE TREATMENTS

Cleaning Texturing Hardening Alloying Cladding


Remelting Dispersing

@ VITO

Material removal Material Melting and addition of


heating and material
cooling

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LASERHARDENING
= laser heating and self-quenching of steels
 formation of martensite with high hardness in HAZ
Glass fiber coupled diode laser with homogenizing optics

5 mm 17 mm

Depth ~ 0.8 mm
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WHY LASER?

» Applicable for relative complex, thin, deformation and crack


sensitive components
» Local technique, only where it is required
» No quenching medium required (environment)
» Higher hardness than conventional
» No contact:
» No wear of the tool
» No forces on the component
» Good control (pyrometer)

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Confidential – © 2009, VITO NV – All rights reserved
LASER SURFACE TREATMENTS

Cleaning Texturing Hardening Alloying Cladding


Remelting Dispersing

Material removal Material Melting and addition of


heating and material
cooling

COMADEM, June 9-11, San Sebastian


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Confidential – © 2009, VITO NV – All rights reserved
CHANGE IN SURFACE COMPOSITION

Laser alloying
Complete mixture and/or reaction
with substrate

Laser dispersing
Complete mixture and no reaction
with substrate

Laser cladding
Minimal dilution with good
metallurgical bonding with
substrate

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LASER ALLOYING
» Principle
» Complete reaction / mixing of additive and metallic substrate

» Materials
» Steel & light metals
» Carburisation (martensite / carbides)
» Nitriding Gas or solid
» Boriding
» Pure elements: Si, Ni, Co, Cr, B, Mo, Mn,… Solid additive

» Example

TiN + Ti-6Al-4V
Source: Jiang et al.

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LASERDISPERSING
» Principle
» Metallic substrate is laser molten
» Ceramic powder is added to melt pool
» No reaction between substrate and additive + no melting of additive

» Result
» Metal matrix composite coating

» Materials
» Already applied for steel: WC, TiC, Cr3C2, Al2O3, TiN, MoS2
» New for light metals (Al or Ti alloys): SiC, WC, VC, TiB2, TiO2, BN,
B4C, …

Al-alloy + SiC

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LASER CLADDING
• Principle
Powder + inert gas
Or wire

Simultaneous addition
solid material

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LASER CLADDING
Powder in
transportgas
Powder- in
Laser
transportgas

Protective gas
Substrate

Lasrichting
Coating Melt pool

Cladding direction Heat affected zone

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LASER CLADDING INSTALLATION
Glass fiber for
transport of
laser light Robot

Pyrometer & camera

Optics

Powder supply and


protective gas

Cladding
head

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CHARACTERISTICS LASER CLADDING
» Laser
» High power CO2, diode or Nd:YAG
» Mostly in continuous mode but in pulsed mode also possible
(lower heat input)
» Laser beam in order of mm’s
» Proces for production of ‘thick’ coatings (order of 1 mm)
» Typical production speed = 1.5-50 cm²/min for a thickness of 1 mm;
thicker coatings by adding multiple layers
» Local, low heat input, complex, thin, deformation and crack sensitive
components
» High powder yield (>> thermal spraying)
» High-quality coating
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CHARACTERISTICS COATING
» High quality coating
» Small dilution of substrate with coating (5-10%)
 on surface after 1 layer = added material (in contrast to
conventional welding with dilution ~ 50%)
 strong metallurgical bond (>> better than thermal spraying)
» High cooling rate  fine microstructure  high hardness
» Low to no porosity
Laser-
» Excellentmolten
control of coating thickness
» Machining limited
» Large freedom in materials
Cast
structure

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TYPE OF COATINGS

» Cobalt based coatings (Stellite): Co-Ni-Cr-W-C-Mo


(wear resistance up to 200°C)

Stellite 21

steel

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TYPE OF COATINGS

» Cobalt based
» Nickel based: Ni-Cr-B-C-Si-Al-Fe
(wear resistance at higher T)

Inconel 625
Ni-Cr-B (410 HV)

steel

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TYPE OF COATINGS
» Cobalt based
» Nickel based
» Iron based: stainless steel, Fe-Cr-C
(oxidation/corrosion resistance)

M2 steel 730 HV Superduplex RVS

steel

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TYPE OF COATINGS
» Cobalt based
» Nickel based
» Iron based: stainles steel, Fe-Cr-C
» Metal – ceramic composite: carbide, nitride, boride particles in
metal matrix (high hardness, are not dissolved)

Ni + sph. WC

Ni + WC
NiCr + Cr3C2 coating
steel
steel

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TYPE OF COATINGS
» On non-ferro substrates
• Repair of turbine blades of Ti and Ni superalloys
• Increase of wear resistance

Al-12Si
Ti + WC
Ti-6Al-4V
Titanium Aluminium
Titanium

Wear resistance = 16x


higher than Ti-6Al-4V

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Confidential – © 2009, VITO NV – All rights reserved
Outline

» Activities of VITO

» Introduction in laser surface treatment

» Case study 1: Repair of compressor shaft

» Case study 2: Repair of compressor wheel

COMADEM, June 9-11, San Sebastian


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Confidential – © 2009, VITO NV – All rights reserved
CASE STUDY 1
Repair of compressor shaft of steam turbine

Conic coupling; fretting wear of


material

Key-seats present
3.7 m length martensitic stainless steel
1 ton AISI 410 / DIN 1.4006 / X12Cr13 70 mm axial length

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CASE STUDY 1
Repair of compressor shaft of steam turbine

Requirements / challenges
• local repair with final thickness = 2 mm
• minimal deformation
• no influence on microstructure in core of shaft
• no cracks in coating or martensitic stainless steel
• good bonding of added material to shaft (not only mechanical bond)

 Thick coating technique

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CASE STUDY 1
Repair of compressor shaft of steam turbine

Requirements
• local repair with final thickness = 2 mm
• minimal deformation Conventional welding
• no influence on microstructure in core of shaft
• no cracks Conventional welding
• good bonding of added material to shaft Thermal spray

Thick coating technique


 Laser cladding of stainless steel AISI 316

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CASE STUDY 1
Repair of compressor shaft of steam turbine
Preliminary test 1
Goal: determine quality after laser cladding with specified materials
L = 700 mm

φ = 30 mm Stainless steel AISI 410

Multiple laser cladded coatings


Stainless steel AISI 316

Deformation tested at both sides of the bar after laser cladding


 0.02 mm, 0.04 mm

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CASE STUDY 1
Repair of compressor shaft of steam turbine
No cracks in
HAZ
No pores

Small dilution 10 µm
0.5 mm

Smooth 15 mm under cladding


surface

0.5 mm
10 µm

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CASE STUDY 1
Repair of compressor shaft of steam turbine

Hardness testing

0.5 mm

No effect on base material at more


than 0.7 mm depth below laser
cladded coating

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CASE STUDY 1
Repair of compressor shaft of steam turbine
Preliminary test 2
Goal: procedure for laser cladding key-seatings without damage

Use of copper insert No material on Cu Easy removal of insert

Good build up
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Confidential – © 2009, VITO NV – All rights reserved
Outline

» Activities of VITO

» Introduction in laser surface treatment

» Case study 1: Repair of compressor shaft

» Case study 2: Repair of compressor wheel

COMADEM, June 9-11, San Sebastian


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Confidential – © 2009, VITO NV – All rights reserved
CASE STUDY 2
Repair of compressor wheel for steam turbine

Single Double

Mechanical
fasteners

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Confidential – © 2009, VITO NV – All rights reserved
CASE STUDY 2
Repair of compressor wheel for steam turbine

Requirements / challenges
• local repair at top with total height of build up = 4 mm
• minimal deformation; no loosening of mechanical fasteners
• no cracks in coating or 30CrNiMo8 steel
• good bonding of added material to wheel (not only mechanical bond)
• material with high wear resistance

 Laser cladding of stellite 21 (Co -28Cr-5Mo-0.25C-2.5Ni)

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Confidential – © 2009, VITO NV – All rights reserved
CASE STUDY 2
Repair of compressor wheel for steam turbine
Preliminary tests
Goal: procedure for laser Goal: quality of stellite 21 coating
cladding straight build up on edge on 30CrNiMo8

• No cracks / no pores
Multiple layers in different laser • HV (stellite 21) = 457 ± 8
orientations are required

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Confidential – © 2009, VITO NV – All rights reserved
CASE STUDY 2
Repair of compressor wheel for steam turbine
Final result – Repair single wheel
About 13 passes for build up of
4 mm Spin tested at 20.000 rpm in vacuum

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OTHER EXAMPLES
Repair of turbine blades

Internal & external cladding of tubes

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Thank you for your kind
attention!
Contact: Rosita.Persoons@vito.be
http://www.lcv.be

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