GTV Presentation GTV Presentation - Laser Cladding - g GTV - - PowerPoint PPT Presentation

▶
gtv presentation gtv presentation laser cladding g
SMART_READER_LITE
LIVE PREVIEW

GTV Presentation GTV Presentation - Laser Cladding - g GTV - - PowerPoint PPT Presentation

Oct 13, 2023 199 likes •617 views

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30 GTV Presentation GTV Presentation - Laser Cladding - g GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach,

slide-1
SLIDE 1

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

GTV Presentation GTV Presentation

  • Laser Cladding -

g

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: + 49 2662 9576-0; fax + 49 2662 9576-30

slide-2
SLIDE 2

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

GTV Cooperation Partners

Laserline Mühlheim

  • Laserline, Mühlheim

High Power Diode Lasers

  • IPG, Burbach

,

Fibre Lasers

slide-3
SLIDE 3

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

GTV Cooperation Partners

HighYag Stahnsdorf

  • HighYag, Stahnsdorf

Laser Optics and Fibres

1 mm

slide-4
SLIDE 4

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

GTV Cooperation Partners

Fraunhofer IWS Dresden

  • Fraunhofer IWS, Dresden

Powder nozzles, CAM Software, Research

NiCrBSi - 60% FTC

slide-5
SLIDE 5

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

GTV Laser Cladding Center

4 x 3 x 3 m Laser Booth 6 kW Diode Laser Laserline Optics with camera for process control p KUKA KR30HA - 8 axes Powder Feeder TWIN 3/3 Lathe WSB 1 Turntable DT300

slide-6
SLIDE 6

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Powder Feeders Powder Feeders

slide-7
SLIDE 7

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

GTV Stand alone TWIN MF 2/2

  • Compact design
  • Completely PLC controlled (Siemens S7)
  • 2 Powder feeder hoppers,

pp volume: 0.3 l, 1.5 l, 5.5 l

  • Mass flow controlled carrier gas lines,

2 different gases can be chosen

  • Mixer for homogeneous feed of powder into

disk grooves

  • Different disk grooves for optimal process

t bilit t d f d t b t stability at powder feed rates between 0.5 g/min - 150 g/min

  • Process visualisation on color touchscreen

monitor Siemens TP177B monitor Siemens TP177B

  • Fine gas filters for protection of components
  • Heating jackets available on demand
  • Diff

t t t l i t f il bl

  • Different remote control interfaces available

(PLC inputs, Profi-Bus)

slide-8
SLIDE 8

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

GTV TWIN MF 2/2-PG

  • Compact design
  • Completely PLC controlled (Siemens S7)
  • 2 Powder feeder hoppers (here just one installed),

pp ( j ) volume: 0.3 l, 1.5 l, 5.5 l

  • Mass flow controlled carrier and process gas lines,

2 different gases can be chosen

  • Mixer for homogeneous feed of powder into

disk grooves

  • Different disk grooves for optimal process

t bilit t d f d t b t stability at powder feed rates between 0.5 g/min - 150 g/min

  • Process visualisation on color touchscreen

monitor Siemens TP177B monitor Siemens TP177B

  • Fine gas filters for protection of components
  • Heating jackets available on demand
  • Diff

t t t l i t f il bl

  • Different remote control interfaces available

(PLC inputs, Profi-Bus)

  • Additional monitoring of cooling water possible
slide-9
SLIDE 9

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

GTV TWIN MF 2/2-PG + Operator Panel

  • Compact TWIN MF 2/2-PG Controller without

TP177B operator panel

  • Remote control of all installation components

b TWIN MF 2/2 PG PLC (h dli i l by TWIN MF 2/2-PG PLC (handling incl. robot hand-shake, chiller, filter, laser source, etc.)

  • Large Operator Panel including process
  • Large Operator Panel including process

camera display on second monitor for complete process visualisation

  • Complete Safety-chain with emergency switch

Complete Safety chain with emergency switch

  • Door safety switch can be integrated
  • Special customer demands can be realized
slide-10
SLIDE 10

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Powder Nozzles Powder Nozzles

slide-11
SLIDE 11

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Lateral powder feed nozzles can easily be added to different kinds

  • f laser optics, but show the disadvantage of deposit geometry

depending on cladding direction and reduced deposition efficiency depending on cladding direction and reduced deposition efficiency compared to coaxial feed

slide-12
SLIDE 12

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding For coaxial powder feed different powder nozzles are available for

various manufacturer´ s laser optics tailored for different applications

slide-13
SLIDE 13

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Annular gap powder nozzles are used most frequently in laser

cladding processes and typically permit + /- 30 ° tilting angle without detrimental effect detrimental effect

Typically powder focus 1-2.5 mm and welding seam width < 10 mm

are applied; deposition efficiency can be up to 95% and depending l t 9 k /h d iti t i ibl

  • n laser power up to 9 kg/h deposition rate is possible

COAX 8

slide-14
SLIDE 14

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Annular gap nozzles for 1-inch optics are restricted to laser power

levels of less than 4 kW, but small dimensions permit easier access to various surface areas on complex shaped components various surface areas on complex shaped components

Typically powder focus 1-2.5 mm and welding seam width < 5 mm

are applied; typically up to 4 kg/h deposition rate can be achieved

COAX 9

slide-15
SLIDE 15

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Special powder nozzles for rectangular-symmetrical alignment of pow-

der feed and rectangular focal spot of high power diode lasers permit seam width 8 - 22 mm and bead geometry comparable to PTA seam width 8 22 mm and bead geometry comparable to PTA

Deposition efficiency can be up to 90% and depending on laser power

up to 6 kg/h deposition rate is possible; only metallic powders can be li d ibl i d t i t i l l lif ti applied sensibly in order to maintain long nozzle life time

COAX 11 square

slide-16
SLIDE 16

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Replacement of annular gap powder nozzles by typically 3 or 4

grooves in the inner cone of the powder nozzle to permit any desired tilting angle of laser heads without detrimental effect by gravity tilting angle of laser heads without detrimental effect by gravity

Typically powder focus 2-3 mm and welding seam width < 8 mm are

applied; deposition efficiency can be up to 95% and depending on l t 5 k /h d iti t i ibl laser power up to 5 kg/h deposition rate is possible

COAX 12

slide-17
SLIDE 17

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding For improved access to functional areas to be coated special powder

nozzles with long narrow (typically 30 mm) body are available; grooved powder nozzle cones permit 3D repair and build-up jobs grooved powder nozzle cones permit 3D repair and build up jobs

Typically immersion depths up to 200 mm and maximum spot width

4 mm are applied

High beam quality lasers (Nd:YAG or disk lasers) with < 3 kW power

COAX 13

slide-18
SLIDE 18

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding For cladding of internal surfaces special integrated laser heads permit

coating of interal diameters > 60 mm with < 1,000 mm length

Typically weld seam width < 4 mm is applied for internal coating of Typically weld seam width < 4 mm is applied for internal coating of

automtive engines, turbine or landing gear components

High beam quality lasers (Nd:YAG or disk

lasers) with < 3.5 kW power

COAX 203icu

slide-19
SLIDE 19

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Depending on the depth of internal surfaces concentional powder

nozzles can be applied

For deep coating of internal surfaces adapted laser heads with For deep coating of internal surfaces adapted laser heads with

tailored powder feed and cooling setups have been developed

slide-20
SLIDE 20

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Applications

slide-21
SLIDE 21

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Deposition of protective coatings

Hardfacing of steam turbine edge Wear protection of stone crushers Hardfacing of steam turbine edge to fight erosion by wet steam (Stellite 21) Wear protection of stone crushers (NiBSi/FTC)

slide-22
SLIDE 22

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Deposition of protective coatings

Wear protection of oil drilling tools Wear protection of oil drilling tools (NiBSi/FTC)

slide-23
SLIDE 23

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Deposition of protective coatings

Wear protection of oil drilling tools Wear protection of oil drilling tools (NiBSi/FTC)

slide-24
SLIDE 24

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Deposition of protective coatings

Wear protection of industrial meat knifes Wear protection of industrial meat knifes (Iron based hard alloys)

slide-25
SLIDE 25

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Deposition of protective coatings

Wear and liquid metal corrosion protection Wear protection of cast aluminum Wear and liquid metal corrosion protection

  • f steel mill sink pot rolls (CGL)

(Tribaloy 400, Tribaloy 700) Wear protection of cast aluminum combustion engines (Al2O3/TiO2)

slide-26
SLIDE 26

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Deposition of protective coatings

Wear protection of concrete mixers Wear protection of paper pulp blades Wear protection of concrete mixers (NiBSi/FTC) Wear protection of paper pulp blades (NiBSi/FTC)

slide-27
SLIDE 27

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Deposition of protective coatings

Wear protection of bearings Wear protection of valve body Wear protection of bearings (Stellite) Wear protection of valve body (Stellite)

slide-28
SLIDE 28

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Wire feedstock is typically added laterally in laser cladding processes,

but problems concerning precise positioning of the wire tip result in limitations concerning complex shape bild-ups limitations concerning complex shape bild ups

Special laser heads with e.g. triple beam focus on an axially fed wire

tip permit to overcome such shortcomings

Typically wire diameter 0.8 - 1.2 mm Typically < 6 kW

laser power laser power

Variable focus

diameter

Special wire feed

for cored wires that permit wide that permit wide material spectrum

slide-29
SLIDE 29

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Repair of Ti6242 blisks of aero engines permits higher strength of

blades than wrought material due to epitactic crystal growth in combined cladding / milling machines combined cladding / milling machines

slide-30
SLIDE 30

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Repair of Ti6242 blisks of aero engines permits higher strength of

blades than wrought material due to epitactic crystal growth in combined cladding / milling machines combined cladding / milling machines

slide-31
SLIDE 31

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Repair of expensive components like crankshafts

  • r aero engine housings as well as parts that are

not easily available like old cars piston ring seats not easily available like old cars piston ring seats

slide-32
SLIDE 32

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Rapid Prototyping / Rapid Tooling of moulds

Stellite 21

slide-33
SLIDE 33

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Rapid Prototyping / Rapid Tooling of moulds in combined cladding /

milling machines

slide-34
SLIDE 34

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Hybrid Laser Cladding Processes Inductive heating support of the laser cladding process permits

increased deposition rate; e.g. 8 kg/h deposition rate of Inconel 625 for 4 kW laser and 14 kW induction power source for 4 kW laser and 14 kW induction power source

Inductive heating permits easier welding of and on crack-prone

materials

Typically < 6 mm laser spot diameter, < 8 kW laser power Focus length f

> 177 mm > 177 mm

Total head weight

< 15 kg

COAXpowerline

slide-35
SLIDE 35

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Laser Cladding Rapid Prototyping / Rapid Tooling of moulds using hybrid inductively

supported laser cladding process

slide-36
SLIDE 36

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Hybrid Laser Cladding Processes Heating of powder feedstock by efficient, low-cost oxy-acetylene

flame with injection into the melt pool created by the laser in order to improve the cladding process efficiency significantly improve the cladding process efficiency significantly

Lateral powder feed can be adapted easily; integrated laser heads

with axial feed of pre-heated powder and electrical resistance pre- h ti f i ll f d i d d l t heating of axially fed wires under development

slide-37
SLIDE 37

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Common Laser / TS Applications

Especially in aero engine and industrial gas turbine industries there

are various components that require thermal spray coatings, laser claddings or other laser based process treatments. claddings or other laser based process treatments.

Combined thermal spray / laser process installations give access to

  • ptimized efficiency concerning machine use; additionally some parts

i b th t require both processes on one part.

slide-38
SLIDE 38

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Common Laser / TS Applications

Turbine blade surface engineering tasks:

Functional coatings on turbine balde tips (clearance control and

tit i fi ti ) titanium fire prevention)

Turbine root coatings to prevent cold welding of titanium parts Erosion protection of midspans

Erosion protection of midspans

Droplet impact erosion of wet steam turbine blade edges Hot gas corrosion protective coatings

g p g

Thermal insulation coatings Fatigue life time improvement by laser peening

slide-39
SLIDE 39

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

Common Laser / TS Applications

Zinc pot and stabilizing rolls are typically coated on their mantle with

hardmetal using HVOF , while shaft bearing seats are protected by laser cladding with special iron based alloys. laser cladding with special iron based alloys.

slide-40
SLIDE 40

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: +49 2662 9576-0; fax +492662 9576-30

h k h Thank you very much for your attention! for your attention!

GTV Verschleiss-Schutz GmbH, D-57629 Luckenbach, Germany www.gtv-mbh.de; office@gtv-mbh.de, Fon: + 49 2662 9576-0; fax + 49 2662 9576-30