Heat Treatment and Thermal Coating

Dynamic beam shaping unit "LASSY" during a laser beam hardening process, mounted to a roboter.
© Fraunhofer IWS
Laser beam hardening of a steam turbine blade with integrated process monitoring and control

For component geometries, wear cases and materials where conventional hardening and coating technologies fail, laser technologies offer new solutions for creating wear-resistant surfaces. Fraunhofer IWS is a leader in the research and application of laser-based processes such as laser hardening, laser cladding with powder and wire and laser roll cladding. The range of processes also includes laser shock peening, which induces residual compressive stress fields into the surfaces and thus guarantees a long product life.

Our focus in R&D is on achieving the highest surface rates by using laser power in the multi-10 kW range, increasing efficiency and improving quality. We use innovative beam shaping systems and precise temperature field control to enable economical, reproducible industrial processes. For industrial projects, the requirements of our customers are our most important benchmark, while for publicly funded projects, the benefits for society are the focus of our work.

Our Range of Services Includes:

  • Development and industrial transfer of laser-based processes with high-power lasers for hardening, heat treatment, roll cladding or build-up welding
  • Use of hybrid technologies to optimize process quality and process efficiency, e.g. laser + laser, laser + induction, laser + power source
  • Development of system components for process monitoring and control: Temperature measuring devices, thermal field control, special optics with/without dynamic beam shaping
  • Development of process heads and customer-specific components for laser cladding with powder and wire.
  • Processing of test and prototype samples
  • Complete technology transfer: Integration of laser processes into industrial production and on-site support.
  • Development of customized surfaces and coatings according to the specific requirements of components.

Research Focus

 

Laser Hardening

  • Increasing the wear resistance of surfaces
  • Precise temperature control
  • Processing of special materials and complex components
 

Laser Cladding

  • Powder and wire-based processes
  • Use of hybrid technologies
  • Repair and wear protection
  • From micro to macro, from ultra-precise to high-power processes
 

Laser Roll Cladding

  • Bimetal production
  • R2R joining of metallic sandwich panels
  • Laser roll cladding of bipolar plates
  • High-performance coating using direct plating
 

Further Surface Treatment Technologies

  • Thermal spraying
  • Laser shock peening
  • Laser forming and remelting
 

Systems Technology

  • Temperature detection, process monitoring and thermal field control
  • Dynamic beam shaping
  • COAX processing heads for laser cladding

Highlights

 

Industry Transfer

Laser Hardening of Turbine Blades

Video

Fully Automatic Heat Field Control

Laser Processing of Complex Part Geometries

Projects

LaserPlatt

Laser-based manufacturing of bimetallic semi-finished products for solid plain bearings for use in large components, Timeframe: 07/2020–06/2022 (BMBF)

CHIMERA

Functionalization of laser-structured fiber-reinforced plastic composites by thermal spraying, Timeframe: 05/2021–10/2023 (BMBF, FKZ: 03XP0368)

HP2BPP

High-rate joining of bipolar plates from two half plates, Timeframe: 05/2022–11/2025 (BMDV, National Action Plan Fuel Cell Production (H2GO) FKZ: 03B11027A)

HYPRAEL

Advanced alkaline electrolysis technology for pressurised H2 production with potential for near-zero energy loss, Timeframe: 03/2023–02/2026 (EU-Horizon)

TBC4H2

Thermal Barrier Coatings for greener heat-to-power applications, Timeframe: 36 months (M-ERA.NET 3)

News and Media

 

Press release / 3.4.2023

Lasers Join Lightweight Sandwich Structures

Production of Lightweight Metallic Panels Using the Roll-to-Roll Process

 

News / 11.8.2022

Simulations for 2D Laser Hardening