Writer： admin Time：2019-09-18 03:46:51 Browse：302℃
Customer background
A large industrial maintenance enterprise in Türkiye focuses on the repair service of core parts such as shafts, bearings, hydraulic rods, motors, etc. Its customers cover the fields of ships, energy, heavy machinery, etc. Due to the pain points of large thermal deformation, low bonding strength, and long repair cycle in traditional repair processes such as welding and electroplating, customers urgently need a high-precision and high reliability technical solution to enhance service competitiveness and meet EU environmental regulations.
Customer requirements
1. Adaptability of complex components: The geometric shape of the components that need to be repaired is complex, and traditional processes are difficult to achieve uniform coating
2. Extreme working condition performance improvement: Many workpieces need to withstand high-pressure impacts, and the repair layer needs to have both high hardness (HRC ≥ 55) and corrosion resistance (salt spray test ≥ 1000 hours)
3. Quick delivery requirement: The customer requests that the repair cycle for a single item be shortened to within 8 hours, which is three times more efficient than traditional processes
4. Environmental compliance: Replace high pollution processes such as electroplating and meet the restrictions of harmful substances such as hexavalent chromium under the EU REACH regulation
Our solution
We have customized a 6000W fiber laser cladding system for it, equipped with a six axis 70KG FANUC industrial robot, an internal laser head and a rotary table
Some of our technical suggestions:
1. The base layer is made of nickel based alloy to ensure metallurgical bonding with the substrate (bonding strength ≥ 400MPa), and the functional layer is made of tungsten carbide reinforced iron-based powder, with a surface hardness of HRC58-62 and a wear resistance four times higher than that of the electroplated layer
2. Optimized laser power (1800-4500W) and scanning speed (400-1200mm/min), capable of repairing 12 hydraulic rods or 8 sets of motor shafts in a single day, with an efficiency 5 times higher than traditional arc welding
Implementation results
1. Efficiency breakthrough: The repair cycle has been shortened from 24 hours to 5 hours, customer service capacity has increased by 120%, and the annual repair volume has exceeded 15000 pieces.
2. Cost optimization: The cost of repairing a single item has been reduced to 40% of the electroplating process, saving over 500000 US dollars in annual chemical waste treatment expenses.
3. Performance upgrade: After repair, the service life of the hydraulic rod has been extended from 6 months to 18 months, the fatigue strength of the bearing has been increased by 200%, and the customer's product has passed T Ü V's 1 million cycle testing certification.
4. Green transformation: reduce hexavalent chromium emissions by 8 tons annually, win the "Industrial Ecology Excellence Award" in Türkiye, and help customers win European ship parts repair orders.
Customer reviews
This 6000W device has completely revolutionized our business model. The high-precision crankshaft, which used to be irreparable, can now restore its performance with just one cladding, and customer satisfaction has jumped from 78% to 96%. More importantly, it helped us pass the carbon neutral supply chain audit for our German clients and become a technological benchmark in the European industrial services market. ”——Gokhan， Technical Director