Writer： admin Time：2019-09-18 03:47:34 Browse：304℃
Customer background
The largest cable manufacturing enterprise in India, specializing in the production of metal and plastic wire rods. Its capstans have long been subjected to high mechanical wear and corrosive environments, resulting in frequent problems such as surface wear and dimensional deformation, directly affecting the accuracy and efficiency of wire rod production. Traditional repair processes such as welding and spraying have pain points such as large heat affected zones, substrate deformation, and easy peeling of repair layers. Therefore, we purchased a set of 6000W laser cladding machines from our company.
Customer Requirements
1. High repair accuracy requirements: The surface needs to maintain millimeter level flatness to ensure uniform stretching of the wire
2. Improvement of wear resistance and corrosion resistance: The capstans need to be strengthened in surface hardness (HRC ≥ 50) and corrosion resistance due to long-term contact with high-speed metal wires and coolant
3. Fast delivery and cost control: Traditional process repair cycles can take up to 5-7 days, and material waste is severe, requiring shortened downtime and reduced overall costs
Technical Proposal
1. In625 powder primer, our 106 iron powder cladding second layer
2. Parameter: Line speed: 1400mm/min, offset: 1.5mm, power: 1500W, powder feeding: 0.6r/min, thickness: about 0.3mm
Results
1. Efficiency improvement: The single repair cycle has been shortened from 7 days to 2 days, and the overall cost has been reduced to 1/5 of the procurement of new parts
2. Performance breakthrough: The repaired capstans have been in use continuously (the original life was only 3-4 months), and the surface salt spray corrosion resistance is improved by 200%
3. Environmental benefits: Reduce metal powder waste by 30% and carbon emissions by 80% compared to traditional arc welding
Customer Reviews
This 6000W laser cladding machine not only solves the problem of frequent capstans replacement, but also has a repair layer with uniformity and wear resistance that far exceeds expectations. The significant reduction in downtime has directly increased our production line capacity and become one of the core technologies for enterprises to reduce costs and increase efficiency. ”---Ashok, general manager