Laser cladding advantages and disadvantages 

Laser cladding advantages

Laser cladding is a highly beneficial technology that enhances component performance across several dimensions.

• Technical advantages >
• Economic advantages >
• Environmental advantages >

This combination of benefits makes laser cladding a preferred choice for industries seeking reliable, cost-effective, and environmentally responsible solutions. Each of these advantages will be elaborated in the sections below to give you a deeper understanding of how laser cladding can benefit your operations.

Technical advantages

Laser cladding offers numerous benefits, positioning it as a superior choice for various industrial applications. We distinguish these advantages into several key categories:

1. Superior Coating Quality
   Laser cladding prevents failures due to corrosion, external impacts, bending, or thermal shocks, thanks to intermetallic bonding, high ductility and no porosity (see below).
2. Excellent repair possibilities
   Laser cladding enables cost-efficient and rapid repairs without compromising on quality, thereby extending the lifespan of components and enhancing equipment uptime.
3. Extended component lifetime
   Components treated with laser cladding have a significantly longer service life due to enhanced wear resistance and surface hardness.
4. Versatility in material choices
   Laser cladding can be applied to a wide range of materials, including carbon steels, stainless steels, duplex steel, nickel-based alloys, and more. This versatility allows for customized solutions tailored to specific industrial requirements.
5. Reduced heat-affected zone
   The localized heating of laser cladding minimizes the heat-affected zone (HAZ) around the deposition area. This preservation of the base material’s mechanical properties and microstructure is crucial for maintaining overall component integrity. 
6. High precision and control
   Laser cladding offers unmatched precision in material deposition, ensuring exact coating thickness and placement. This precise control minimizes material waste and reduces post-processing requirements.

Intermetallic Bonding

During laser cladding, an alloy is melted with the base material, creating an intermetallic bond between the two. This process inherently prevents subcorrosion between the laser cladded layer and the base material. In contrast, HVOF and NiCr coatings are not melted but mechanically bonded. These coatings can hold pores and develop cracks, allowing substances like seawater to penetrate the coating, corrode the base material, and eventually push off the coating from the inside out.

No Porosity

Laser clad layers have 0% porosity, forming an impermeable barrier that prevents corrosive fluids from reaching the base material. This feature significantly enhances protection against subcorrosion compared to traditional coatings.

High Ductility

Laser clad layers exhibit exceptional ductility, allowing them to absorb material stress from impacts, bending, and thermal cycling without cracking. This property is critical for components subjected to harsh operational environments as it absorbs high material stress and, consequently, avoids cracking. HVOF and NiCr coatings are not ductile at all; bending, external impacts and thermal shocks will inevitable result in cracking. This high ductility, combined with the intermetallic bonding, prevents heavy damage due to external impacts (e.g. rocks or tools), bending (e.g. long thin rods) and thermal shocks (e.g. steel production process).

Overhaul of heavily damaged products

Severely damaged components can be restored by applying a laser clad layer several millimeters thick. This process avoids the need for costly replacements and lengthy remanufacturing processes. This saves time and resources as the critical parts can be overhauled in days instead of weeks.

Repairability of damaged threads

Laser cladding effectively repairs heavily damaged thread by removing and re-cladding material, resulting in thread with higher tensile strength than standard carbon steel. Cladded thread prevents corrosion and hence ensures smooth disassembly of threated counterparts such as piston rod eyes.

On-site repair capability

Minor damages can be repaired on-site using standard TIG welding equipment, eliminating the need for component disassembly and minimizing downtime.

Economic advantages

Investing in laser cladding translates into substantial economic benefits for your business.

Lower total cost of ownership (TCO)

In many industries the uptime of capital intensive equipment is crucial for economic success. The technical advantages of Topclad Laser Cladding ensure superior protection against corrosion, wear, external impact, bending and thermal shocks. These premium properties, combined with the excellent repair possibilities, significantly increase the lifetime of essential components as well as the uptime of the related equipment. The total costs of ownership are substantially reduced with Topclad Laser Cladding.

Use of low-cost base material

Rising raw material prices and long lead times have become the norm rather than the exception. High-grade materials, such as stainless steel and duplex, are particularly affected. Many companies are re-evaluating their product designs to mitigate the impact on their operations. The Topclad laser cladding layers provide a solution by substituting expensive stainless steel or duplex base materials. Components like piston rods, rollers, and drums can be made from much cheaper regular carbon steel—with higher yield strength—combined with an optimized Topclad laser cladding layer. Carbon steel with a Topclad laser cladding layer is more affordable, has shorter lead times, and offers a longer service life.

One-stop shop

Topclad has close collaborations with local machine shops. Through these partnerships short lead times and low costs can be achieved on sourcing material, machining and laser cladding of components. Topclad takes care of your complete component.

Environmental advantages

We help you achieve your environmental goals without compromising on performance and reliability. By using our laser cladding technology, your components last longer, waste is minimized, and the use of hazardous substances is reduced, significantly lessening the environmental impact of your operations. At Topclad, sustainability is at the heart of everything we do, ensuring your business remains efficient and eco-friendly.

By choosing laser cladding, you contribute to environmental conservation while achieving superior performance and durability for your industrial applications.

Chromium-6-free coatings

Chromium-6 is a chemical commonly used in various industrial coatings, but it is associated with serious health risks. As a result, the European Commission has significantly restricted its use, and a complete ban is expected to be imposed following the current regulations. The European Chemicals Agency (ECHA) has proposed a phase-out of chromium-6 in certain applications, aiming to eliminate its use entirely. Topclad laser cladding layers are free from chromium-6, ensuring that our customers are well-prepared for a more sustainable future.

Laser cladding disadvantages

While laser cladding offers numerous benefits, understanding its potential drawbacks is crucial for making an informed decision:

• High initial costs: Setting up for laser cladding can be costly due to the sophisticated equipment required. However, Topclad provides services that mitigate the need for upfront capital investment, allowing access to this advanced technology without significant initial expenditure.
• Complexity: Laser cladding involves detailed operations requiring skilled operators and precise control over numerous process parameters. With over 14 years of experience and more than 13,000 rods successfully treated, Topclad has mastered the complexities of this process. Our extensive experience ensures that we consistently deliver optimal results, leveraging our deep understanding and advanced technology to handle even the most challenging projects.

Understanding these challenges highlights why Topclad is the preferred partner for your industrial coating needs. Our commitment to excellence ensures the delivery of the highest quality services and results, specifically tailored to meet your unique requirements. Explore our detailed approach in our Laser Cladding Applications and learn more about the markets we serve on our Market Segments page.