Laser cladding technology has become the preferred solution for crankshaft repair

Laser cladding technology emerged in the 1980s, utilizing a high-energy-density laser beam to melt materials with special properties onto the base material, forming an

alloy cladding layer with completely different composition and performance from the matrix. It is an emerging technology.

In the modern petrochemical industry, a continuous and scaled production model is adopted, with tight connections between upstream and downstream units. The

stability of equipment production directly affects the stability of the production line. Due to prolonged operation in harsh environments, mechanical equipment is prone

to corrosion and wear, imposing high requirements on the reliability, safety, and integrity of the equipment used.

Typical failure-prone components in the petrochemical industry include the blades, shaft journals, discs, bushings, and bearings of large rotors, as well as the large rotors,

moving blades, and stationary blades of large generator units.

The repair of large rotors and shaft components using laser cladding technology allows for the restoration of shaft journal dimensions without preheating the workpiece,

resulting in minimal subsequent machining and a reduced risk of metallurgical cracking. The hardness can reach above HR60, and the strength of the finished parts after

repair can even surpass 90% of the original strength. Importantly, the maintenance cost is less than 1/5 of the replacement cost. Moreover, the shortened overhaul time

addresses the continuous operation issues of major equipment in the petrochemical industry, a crucial requirement for rapid repairs.

Additionally, laser cladding with super-wear-resistant and corrosion-resistant alloys on the surfaces of critical components can significantly extend their lifespan without

causing deformation. Laser cladding on mold surfaces not only enhances mold strength but also reduces manufacturing costs by two-thirds and shortens manufacturing

cycles by four-fifths.

For crankshaft repair, plasma spraying may not ensure sufficient bond strength between the coating and the substrate, potentially affecting the safe operation of the

equipment after reassembly. On the other hand, surface welding is challenging to guarantee the wear resistance of the repair layer and the absence of cracks in the base

material. Given these considerations, laser cladding technology has become the preferred solution for repair.

Advantages of laser cladding in crankshaft repair:

Optimized surface performance:Laser cladding can form alloy coatings on the crankshaft surface that fuse with the substrate, exhibiting completely different composition

and performance. The thin base layer minimally influences the composition of the cladding layer, allowing tailored coatings with heat resistance, corrosion resistance, wear

resistance, oxidation resistance, fatigue resistance, or optical, electrical, and magnetic properties to be prepared, effectively enhancing crankshaft surface performance.

High metallurgical bond strength: During the laser cladding process, the added cladding material completely melts, becoming the main alloy of the cladding layer.

Simultaneously, a thin base alloy is also melted, forming a metallurgical bond with the target alloy. This bond is not easily detached, addressing the issue of weak bond

strength between coating and substrate in traditional processes such as electroplating and spraying.

Low heat input and minimal deformation: Laser cladding involves rapid heating and cooling, with minimal impact on the base material and a dilution rate of ≤5-8%.

This resolves a series of technical challenges associated with traditional hot welding processes, such as electric welding and argon arc welding, including inevitable thermal

deformation processing and heat fatigue damage.

Applicable to various materials: Laser cladding can prepare coatings of various alloys, including iron-based, nickel-based, cobalt-based, copper-based, and composite

materials.

I provide various powders suitable for laser cladding on crankshafts, including iron-based, nickel-based, cobalt-based, copper-based, and composite materials. Powder

selection solutions can be tailored according to specific working conditions. For more details, please contact: Amy Wu, Email: srmi@cobaltchromiumalloy.com.