Laser Direct Plating

Laser direct plating opens up new possibilities for the energy-efficient coating of large-format, rotationally symmetrical components. In contrast to conventional processes, no powder is used, but rather tape-shaped coating material. This is laid spirally around the base body and heated locally in the joining gap with the aid of a laser. A pressure roller ensures that the tape is bonded to the component. In this way, layers several millimeters thick can be applied reliably and homogeneously – with application rates of up to 100 kilograms per hour and significantly reduced energy consumption.

Advantages Over Other Processes

The direct cladding process developed at Fraunhofer IWS reduces energy consumption by a factor of five compared to established processes. Since the material is not completely melted, the thermal load on the components is significantly reduced. At the same time, reproducible layer thicknesses of up to several millimeters are achieved, which can be used without additional processing. This significantly shortens process times and noticeably reduces production costs.

• Very high deposition rates (50–100 kg/h)
• Reduced thermal stress on components
• High layer homogeneity and surface quality
• 100% material utilization, no overspray
• Low energy consumption compared to alternative processes
• Fast, low-emission, and low-noise process

Materials and Applications

A wide variety of materials can be processed—from stainless steels, bronze, brass, and copper to nickel- and cobalt-based alloys. Planned applications include:

• Reconditioning of work rolls
• Coating of large hydraulic cylinders
• Direct application of bearing materials
• Integration of spiral cooling channels

Key Technical Data

• Dimensions of blanks/base bodies: Round material from Ø 80 to 400 mm, max. 2000 mm length
• Finished part: max. Ø 500 mm
• Max. 2.5 t component weight
• Coating material: 5-22 mm width, max. 3 mm thick strips