Conventional solid-state lasers are typically pumped with high-power gas discharge lamps with pumping efficiencies of approximately 3% to 6%. The large amount of energy emitted by the pump lamp is converted into heat energy, which not only causes the solid laser to adopt a cumbersome cooling system, but also a large amount of thermal energy causes a thermal lens effect that cannot be eliminated by the working substance, which deteriorates the beam quality.
Laser cladding, also known as laser cladding or laser cladding, is a new surface modification technology. It forms an additive cladding layer that is metallurgically bonded to the surface of the substrate by adding a cladding material to the surface of the substrate and using a high energy density laser beam to fuse it with a thin layer of the substrate surface.
Dazu Jinshikai is a professional provider of high-power laser processing solutions. Leading products include: high-power laser series, high-power laser welding equipment series, high-power laser cutting equipment series, laser heat treatment equipment series, laser cladding equipment series, laser rapid manufacturing equipment, etc. More than 40 different types of lasers Processing equipment and its ancillary products. These products have independent intellectual property rights and are widely used in iron and steel metallurgy, petroleum, metal materials processing, tobacco and paper processing, hardware tools, automotive, machinery, aerospace, chemical, home appliance manufacturing and other industries, and have overcome many of these industries. Technical problems, won the first place in the market segment of laser heat treatment equipment, high-power laser welding equipment, cigarette laser drilling equipment and other market segments.
Laser cladding means that a selected coating material is placed on the surface of the substrate to be coated by a laser beam to be melted simultaneously with a thin layer on the surface of the substrate, and rapidly solidified to form a very low dilution. A surface coating that is metallurgically bonded to the substrate to significantly improve the wear, corrosion, heat, oxidation and electrical properties of the surface of the substrate to achieve surface modification or repair, which not only meets the surface specificity of the material. The performance requirements save a lot of valuable elements.
Compared with surfacing, spraying, electroplating and vapor deposition, laser cladding has the characteristics of small dilution, compact structure, good coating and matrix bonding, suitable for cladding materials, large changes in particle size and content, etc. The application prospects are very broad.
From the current application of laser cladding, it is mainly used in two aspects: first, surface modification of materials, such as gas turbine blades, rolls, gears, etc.; second, surface repair of products, such as rotors, molds Wait. Relevant information shows that the strength of the repaired parts can reach more than 90% of the original strength, and the repair cost is less than 1/5 of the replacement price. More importantly, the repair time is shortened, and the continuous and reliable operation of the major complete sets of equipment of large enterprises is solved. The problem of rapid repair of rotating parts that must be solved. In addition, by laser cladding the super wear-resistant resist alloy on the surface of the key components, the service life of the components can be greatly improved without deforming the surface of the components; laser cladding treatment on the surface of the mold not only improves the strength of the mold, but also improves the strength of the mold. It can reduce manufacturing costs by 2/3 and shorten the manufacturing cycle of 4/5.
Cladding materials: Currently widely used laser cladding materials are: nickel-based, cobalt-based, iron-based alloys, tungsten carbide composites. Among them, nickel-based materials are the most widely used, and they are cheaper than cobalt-based materials.
Cladding process: Laser cladding can be divided into two major categories according to the supply method of cladding materials, namely preset laser cladding and synchronous laser cladding.
The preset laser cladding is to place the cladding material on the cladding portion of the surface of the substrate in advance, and then scan and melt by laser beam irradiation. The cladding material is added in the form of powder, silk and plate, and the powder is the most Commonly used.
Synchronous laser cladding is the direct feeding of the cladding material into the laser beam, so that the feeding and cladding are completed simultaneously. The cladding material is also mainly fed in the form of powder, and some are also fed by wire or plate. The main process flow of the preset laser cladding is: pretreatment of the substrate cladding surface---pre-cladding material---preheating---laser melting---post-heat treatment.
The main process flow of synchronous laser cladding is: pretreatment of substrate cladding surface---feeding laser melting---post-heat treatment.
According to the process flow, the processes related to laser cladding are mainly the substrate surface pretreatment method, the cladding material feeding method, the preheating and the post heat treatment.
How the laser works:
Laser cladding complete equipment: laser, cooling unit, powder feeding mechanism, processing table, etc.
Selection of lasers: CO2 lasers and solid-state lasers are widely used.
CO2 laser is the most widely used and widely used laser. It is widely used in the automotive industry, steel industry, shipbuilding industry, aviation and aerospace industry, motor industry, machinery industry, metallurgical industry, metal processing and other fields. It accounts for 40% of global industrial laser sales and 70% in North America.
1. High power. The CO2 laser is one of the lasers whose output power reaches the highest level, and its maximum continuous output power can reach several tens of thousands of watts.
2. High efficiency. The photoelectric conversion rate can reach more than 30%, which is much higher than other processing lasers.
3. The beam quality is high. The mode is good, the coherence is good, the line width is narrow, and the work is stable.
Conventional solid-state lasers are typically pumped with high-power gas discharge lamps with pumping efficiencies of approximately 3% to 6%. The large amount of energy emitted by the pump lamp is converted into heat energy, which not only causes the solid laser to adopt a cumbersome cooling system, but also a large amount of thermal energy causes a thermal lens effect that cannot be eliminated by the working substance, which deteriorates the beam quality. In addition, the life of the pump lamp is about 400 hours, the operator needs to spend a lot of time to change the lamp frequently, interrupt the system work, and greatly reduce the efficiency of the automated production line. Compared to conventional lamp-pumped lasers, diode-pumped solid-state lasers have the following advantages:
(1) High conversion efficiency: Since the emission wavelength of the Semiconductor laser is consistent with the absorption peak of the solid laser working substance, the pump light mode can be well matched with the laser oscillation mode, so that the light-to-light conversion efficiency is high. More than 50%, the overall efficiency can also be comparable to that of carbon dioxide lasers, which is an order of magnitude higher than that of lamp-pumped solid-state lasers. Therefore, diode-pumped lasers are small, lightweight, and compact.
(2) Reliable performance and long life: the life of the laser diode is much longer than that of the flash lamp, up to 15,000 hours. The energy stability of the pump light is good, one order of magnitude better than the flash pump, and the performance is reliable. It is a fully cured device and is the only one so far. Maintenance-free lasers are especially suitable for large-scale production lines.
(3) Good output beam quality: Due to the high conversion efficiency of the diode-pumped laser, the thermal lens effect of the laser working substance is reduced, and the output beam quality of the laser is greatly improved, and the laser beam quality is approaching the limit.
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