Laser cladding for rollers & drums
Rollers and drums are crucial components used across various industries, including food processing, steel manufacturing, mining, and offshore operations. These parts are constantly exposed to abrasive materials, chemical fluids, high mechanical stress, temperature fluctuations, and corrosive environments. Laser cladding offers a highly effective solution for both new and worn-out rollers and drums by applying a protective layer that enhances their durability and lifespan. For new products, laser cladding provides preventive protection, while worn-out parts can be restored to their original dimensions. With the added benefit of a metallurgical bond, there is no risk of layers detaching, making laser cladding a highly reliable option for critical components.
Typical properties and key considerations for rollers & drums
Rollers and drums have specific properties and operational requirements depending on the industry. Here are some critical points:
- Wear Resistance: In industries like steel manufacturing, mining, and recycling, rollers are exposed to continuous friction and abrasive materials. Cladding solutions such as Tardisphere provide excellent wear resistance, ensuring a longer service life and reducing the need for frequent maintenance.
- Dimensional Integrity: Rollers and drums in industries like paper production or textiles must maintain precise dimensions to ensure smooth operation. Laser cladding is highly effective at restoring these components to their original dimensions without compromising the surface integrity, ensuring seamless functionality.
- Corrosion Resistance: In environments where rollers are exposed to corrosive fluids, such as in food processing or offshore operations, the Quarite-series offers superior corrosion resistance without the risk of peeling off. This ensures that the rollers maintain their integrity and performance, even in the harshest conditions. The metallurgical bonding of laser cladding ensures there’s no risk of loose particles contaminating food, making it an excellent solution for food-grade applications
- Temperature Fluctuations: In applications where rollers and drums experience significant temperature changes, Topclad laser clad layers provide high thermal shock resistance, ensuring the materials retain their structural integrity under thermal stress.
- Chemical Resistance: Rollers in industries exposed to aggressive chemicals, like food processing and chemical manufacturing, benefit from the superior chemical resistance of the Quarite-series, protecting them against chemical substances without compromising their performance.
Maintenance and repair for rollers & drums
Over time, rollers and drums experience significant wear and corrosion due to constant friction and exposure to harsh environments. For instance, in industries like food processing, where aggressive lyes and acids are frequently used, chemical resistance becomes crucial. Quarite N is an ideal solution for these environments due to its exceptional protection against chemical attack. The metallurgical bonding of laser cladding eliminates the risk of loose particles contaminating food, making it an excellent choice for food-grade applications.
Often, the bearing surfaces endure the most wear due to high mechanical loads and continuous rotation. Applying Topclad’s Tardisphere layer reinforces these critical areas with both wear and corrosion resistance, significantly extending their durability. Additionally, laser cladding can restore bearing surfaces and other roller/drum areas to their original dimensions with precision, enhancing overall product performance.
Beyond just repairing bearing surfaces, cladding the entire roller or drum provides greater benefits. Given the size, weight, and intrinsic value of these components—up to 60 tons and 2200 mm in diameter—laser cladding is a cost-effective solution for protecting new products and restoring worn-out parts to their original specifications. This approach not only reduces the risk of breakdowns but also extends the equipment’s operational life, making it a preventive improvement by upgrading the material properties beyond the original.
Laser clad layers for rollers & drums
Stainless Steel 316 is a versatile and durable alloy known for its corrosion resistance, particularly in harsh environments
Sinex replaces full material stainless steel with a laser clad layer on carbon steel, matching 316L's properties.
Optimized for many applications, Quarite N offers excellent corrosion resistance and strong chemical & thermal propertie
Quarite NR provides the highest corrosion resistance in the Topclad portfolio, ideal for environments with extreme corrosion and moderate wear demands.
Quarite NR+ combines exceptional corrosion resistance (equal to NR) with enhanced wear resistance, making it perfect for harsh, most challenging environments.
Specially developed to combine the best of both worlds—excellent corrosion resistance and high wear resistance—without using carbides.
Topclad’s expertise in rollers & drums
At Topclad, we offer customized laser cladding solutions for rollers and drums, tailored to meet the specific needs of your industry. Our cutting-edge technology creates a metallurgical bond with the base material, ensuring a long-lasting and reliable solution. Whether for new or existing components, laser cladding is a proven method for maximizing the performance of your rollers and drums while minimizing downtime.
Learn more about our laser cladding solutions and contact us today to discover how Topclad can extend the life of your rollers and drums with our advanced technology. Request a quote to start optimizing your operations with Topclad’s expertise.
Repair of rollers & drums
Markets
Laser cladding for rollers & drums is used in these industries:
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Topclad Laser Cladding is the leading manufacturer of innovative laser clad layers in Europe. Based in Lelystad, the Netherlands, Topclad Laser Cladding develops and applies laser clad layers for the most demanding industries including oil, gas, sustainable energy, offshore, dredging, mining, bridges and water locks, steel manufacturing and food processing.
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We are Topclad
Topclad is Europe’s leading manufacturer of innovative laser clad layers, based in Lelystad, the Netherlands. We specialize in developing and applying laser clad layers for the most demanding industries, including oil & gas, offshore, dredging, mining, bridges & water locks, steel manufacturing, and food processing.
Our mission is to provide components with superior protection against wear, corrosion, and impact, resulting in significantly improved reliability and uptime of capital-intensive equipment. With over 14 years of experience and a steadfast commitment to quality, we deliver solutions that enhance the performance and longevity of your critical machinery.
Why Topclad?
- Over 14 years laser cladding experience with over 10.000 cladded components
- More than 10 in-house developed laser clad layers
- Commitment to quality
- Expertise in comprehensive repairs
- 24.000 mm clad length capacity and 2.200 clad diameter capacity
- Chromium-6-free solutions
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