Laser cladding equipment typically includes the following components:
1. Laser system:
This is the main component of the equipment, which produces the laser beam used for cladding. It consists of a laser source, beam delivery system, and controls. Commonly used laser light source manufacturers include：IPG / Trump / Max etc. Usually the power of laser light source is 3KW / 6KW / 12KW / 20KW etc.
If you choose an ordinary laser head on the market, you generally need to match the core diameter of the laser, which is 600-800 um. Such a thick core diameter is to increase the diameter of the laser convergence point and disperse the energy, but it does not truly homogenize the spot energy. , its distribution is still Gaussian spot energy distribution,
But if you choose an annular spot cladding head, you do not need to choose a light source with a large core diameter. You can use a cutting light source. Their core diameter is generally about 100 um, and the small core diameter is annually homogenized. After treatment, it is more suitable for laser cladding. For the advantages of ring laser cladding, please refer to this blog.
Picture a, typical Gaussian laser single-mode energy distribution, mainly used for cutting, drilling, cleaning, etc.
Picture b is a schematic diagram of the energy distribution of a flat-top multi-mode laser. The spot energy is evenly distributed and is suitable for laser welding, quenching, cladding, etc.
In addition, if you have chosen the brand and power of the laser light source, there is another very important thing, which is the fiber interface. This is very important. According to our many years of experience, laser cladding applications are becoming more and more high-power. Well, the first thing we recommend is the integrated connector form, and the principle quick-plug form is no longer recommended. Of course, this is a recommendation for high power above 6KW. If you use a light source with a power of about 3KW, it doesn’t matter.
2. Cladding head:
The cladding head is responsible for focusing and directing the laser beam onto the workpiece. It often includes a focusing lens, nozzle, and powder feeding mechanism.
The laser cladding head belongs to the external shaping optical path part. According to the form of beam transmission, it can be divided into transmission cladding and reflection cladding heads. The principle is shown in the figure below:
The picture shows the transmission optical path.
The picture shows the reflective light path.
We have learned about the transmission form of the optical path above, so what will the corresponding laser cladding look like? You can understand intuitively through the figure below.
how do you generally choose a laser cladding head?
The first thing to consider is the type of workpiece that the customer wants to process. If it is a small piece, repair type part, or 3D printing, then the transmission type cladding head is preferred; the transmission type is suitable for medium and low power cladding applications;
If the size of the workpiece is relatively large and large-format cladding is processed, a reflective cladding head is recommended. The reflective type generally uses a copper mirror lens, has its own water cooling, and can withstand high-power laser cladding.
3. Powder feeder:
The powder feeder is used to supply the cladding material (usually in powder form) to the cladding head. It can be either a gravity-fed or a pressurized system.
Powder feeders can be divided into two types according to their working modes, gravity powder feeding and airborne powder feeding. The gravity powder feeder is shown in Figure a. The principle is to feed the powder by sliding down due to the gravity of the powder. Of course, there is an internal motor to adjust the speed of the powder. Rayclad’s gravity powder feeder is actually a combination of gravity and air 2 It has a spare ventilation interface. The gravity powder feeder is generally used in conjunction with the reflective copper mirror cladding head.
The airborne powder feeder is shown in Figure b. It is typically a double-cylinder type. The airborne powder feeder relies on air pressure to blow the powder out along the pipe. It is usually equipped with a transmission cladding head. There are 4 types of powder feeding nozzles. 6-way, annular nozzle.
4. Workpiece positioning system:
This system allows for precise positioning and movement of the workpiece during the cladding process. It may include a rotary table, linear stages, or robotic arms.
The picture below shows the positioning fixture for agricultural machinery blades.
5. Gas supply system:
Depending on the cladding process, various gases may be used, such as shielding gas to protect the clad material from oxidation, or reactive gas for certain applications. The gas supply system provides the necessary gases to the cladding head.
Inert gases: The commonly used inert gases include argon and nitrogen. Inert gases are primarily used as shielding gases to prevent oxidation or chemical reactions of the cladding material at high temperatures. Argon gas is the most commonly used inert gas as it does not react with most materials at normal temperatures.
Reactive gases: For certain special applications such as alloying cladding, reactive gases like oxygen or nitrogen may be used. These gases can chemically react with the cladding material, altering its chemical composition or properties.
Hydrogen gas: Hydrogen gas is sometimes used in certain cladding processes. It can be used to remove oxides or other impurities in the cladding layer and improve the quality of the cladding.
It is important to consider the characteristics of the cladding material and specific process requirements when selecting and using gases. Different gas combinations and flow rate settings can have critical effects on the outcomes of the cladding process, and thus adjustments should be made accordingly. Additionally, safety and operational guidelines should be followed when handling gases to ensure a safe working environment for the operators.
6. Control software:
The equipment is typically controlled by specialized software, which allows for the configuration of process parameters, monitoring of the cladding process, and adjustment of laser power, powder feed rate, and other variables.
7. Cooling system:
Laser cladding generates a significant amount of heat, so a cooling system is required to dissipate the heat from the equipment components.
The water cooler mainly depends on the water flow required by the laser. A small part is used to cool the laser head. All water coolers have different power sizes.
8. Safety features:
Laser cladding equipment should include safety features such as enclosed work areas, laser safety interlocks, and controls to prevent accidental exposure to laser radiation.
9. Auxiliary equipment:
Depending on the specific application, additional equipment may be needed, such as a powder recovery system, dust collector, or post-processing equipment for surface finishing.
It’s important to note that the specific equipment list may vary depending on the manufacturer, model, and intended application of the laser cladding system.
