Professional Documents
Culture Documents
Materials Technology
materials processing
» Activities of VITO
@ VITO
5 mm 17 mm
Depth ~ 0.8 mm
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Confidential – © 2009, VITO NV – All rights reserved
WHY LASER?
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Confidential – © 2009, VITO NV – All rights reserved
LASER SURFACE TREATMENTS
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
» 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.
» 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
Simultaneous addition
solid material
Protective gas
Substrate
Lasrichting
Coating Melt pool
Optics
Cladding
head
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Confidential – © 2009, VITO NV – All rights reserved
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
COMADEM, June 9-11, San Sebastian
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Confidential – © 2009, VITO NV – All rights reserved
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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Confidential – © 2009, VITO NV – All rights reserved
TYPE OF COATINGS
Stellite 21
steel
» Cobalt based
» Nickel based: Ni-Cr-B-C-Si-Al-Fe
(wear resistance at higher T)
Inconel 625
Ni-Cr-B (410 HV)
steel
steel
Ni + sph. WC
Ni + WC
NiCr + Cr3C2 coating
steel
steel
Al-12Si
Ti + WC
Ti-6Al-4V
Titanium Aluminium
Titanium
» Activities of VITO
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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Confidential – © 2009, VITO NV – All rights reserved
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)
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Confidential – © 2009, VITO NV – All rights reserved
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
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Confidential – © 2009, VITO NV – All rights reserved
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
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Confidential – © 2009, VITO NV – All rights reserved
CASE STUDY 1
Repair of compressor shaft of steam turbine
No cracks in
HAZ
No pores
Small dilution 10 µm
0.5 mm
0.5 mm
10 µm
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Confidential – © 2009, VITO NV – All rights reserved
CASE STUDY 1
Repair of compressor shaft of steam turbine
Hardness testing
0.5 mm
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Confidential – © 2009, VITO NV – All rights reserved
CASE STUDY 1
Repair of compressor shaft of steam turbine
Preliminary test 2
Goal: procedure for laser cladding key-seatings without damage
Good build up
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Confidential – © 2009, VITO NV – All rights reserved
Outline
» Activities of VITO
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
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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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Confidential – © 2009, VITO NV – All rights reserved
OTHER EXAMPLES
Repair of turbine blades
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Confidential – © 2009, VITO NV – All rights reserved
Thank you for your kind
attention!
Contact: Rosita.Persoons@vito.be
http://www.lcv.be