LCV developed an alternative to wet wire drawing pulleys from refined steel. This is expensive and demands wear-resistant tools during production. LCV made new pulleys from low carbon steel and applied a wear-resistant Ni-WC coating to the running edge for the wires. This is cheaper and easier to machine. Moreover, in the case of wear only the coating needs to be replaced and the original dimensions are restored.
Another application comes from combustion technology, or more specifically the surface welding of Incoloy 800 HT burner nozzles for transporting powdered carbon to the combustion chamber of powder-coal plants. In order to reduce abrasive and corrosive wear of the burner nozzles, a Stellite 21 coating is applied both internally and externally to the end that enters the combustion chamber.
A section of the filter unit from glass production technology is subject to wear and corrosion. This section of the pipe was made on the basis of Ni. The section of the filter unit to be sealed is subject to wear. This section of the corrosion proof pipe was clad with a harder Ni-based alloy. (400 HV)
In order to repair a die to produce coat hooks, we applied a thin wear-resistant layer based on Ni-WC. Large dies that are subject to wear or to other failures can be repaired without deformation while retaining their hardness. Most die materials contain a higher C, but can be clad crack-free. In principle, other coating materials than Ni-WC are also possible.
For repairing compression impellers on the outside edge, laser surface welding is the only suitable technique for the realisation of a coating with metallurgical binding without the impeller deforming.
The impellers are built from a top and bottom plate which are connected to each other with rivets. This construction makes it impossible to surface weld the impellers in the traditional way because the large heat-input during surface welding results in the deformation of the two impeller halves and so can result in the halves coming loose. Moreover, during traditional surface welding, cracks form at the location of the rivets, which are at a distance from the zone that is to be repaired.
The process from cog wheel design to the final production by means of milling is very long (work preparation and adjustment times). By making use of 3D printing, more specifically by Laser Cladding, the cog wheel can be constructed on an axle in three hours. After that, only the surface needs to be finished.
Besides the construction itself, the laser cladding process can provide more functionality to the end product. For instance, the core of the cog wheel is made from a more ductile steel while the outside surfaces are clad with a hard and so more wear-resistant coating.
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