Carbide Hardfacing with Tungsten Carbides
Targeted deposition of carbide-containing hard layers with homogeneous carbide distribution – without thermal destruction of carbides as occurs with arc-based processes.
Laser cladding, internationally also known as Laser Cladding or Laser Metal Deposition (LMD), is the high-end process of industrial coating and repair technology. A focused laser beam locally melts the component surface while powder or wire as filler material is precisely introduced into the emerging weld pool.
Characteristic features are the very targeted heat input, an extremely low dilution with the base material – frequently below 2 percent – and a near-net-shape layer build-up. Component geometry and properties of the base material are largely preserved; distortion is reduced to a minimum.
Layers as thin as 0.15 to 0.50 mm already achieve the hardness and wear properties that conventional processes only deliver after several passes. Laser cladding thus covers applications where precision, carbide retention, reproducibility and automation are required – from hardfacing with tungsten carbides to the additive build-up of complex geometries.
Laser Cladding for Precision Wear Protection, Repair and Near-Net-Shape Coating
We deploy laser cladding specifically when demanding components need to be locally reinforced, precisely coated or built up in near-net-shape. Through the choice of powder or wire filler, spot size and process management, wear, corrosion and functional layers can be exactly matched to the loading – including in difficult positions, on complex geometries and with defined carbide content.
Near-Net-Shape Coating of Demanding Components
Functional layers at thicknesses from 0.15 mm – often without costly post-processing such as diamond grinding, because the layer is already applied in near-net-shape.
Repair and Restoration of Worn Functional Surfaces
Local repair of worn components or restoration of lost functional surfaces – quickly, economically and with full metallurgical bonding.
Powder- and Wire-Based Material Deposition
Powder is introduced into the weld pool via nozzles; wire is fed laterally or at capilla centrically. Both variants allow precise material dosing and fine layer control.
Laser 3D Printing and Additive Build-Up
In urgent cases or when spare parts are unavailable, complex geometries can be built up at short notice with equivalent function via Laser Metal Deposition – additively and with defined material properties.
Contact us with any questions:
We support you in selecting the right welding process and the appropriate solution.
The right laser process for your application
Not every load requires the same solution. That is why in laser cladding we deliberately rely on different wire systems in order to repair or protect components economically, precisely and durably. With laser flux-cored wire and laser solid wire we offer two processes with clear strengths for different requirements.
Laser flux-cored wire
Laser flux-cored wire is used when there are the highest demands on wear protection, hardness levels and individual material properties. Thanks to the filled wire structure, alloys can be specifically adapted in order to optimally design components for abrasive, corrosive or thermal loads.
The process is particularly suitable for heavily stressed components in recycling, extrusion or conveying technology. Advantages are high flexibility in material selection as well as wear resistance. At the same time, the low heat input of the laser process ensures minimal deformation and a precise coating.
Laser solid wire
Laser solid wire is used above all when uniform, clean and precise coatings are required. The process is ideally suited for applications with high demands on surface quality, dimensional accuracy and reproducible results.
Advantages are high process reliability, low spatter formation as well as a very fine and controlled deposition structure. It is particularly suitable for precise repairs, thin-walled components and applications with tight tolerances.
Wear Protection in Practice: Carbide Laser Hardfacing on a Drill Bit
Drill bits and boring tools in mining, tunnelling and processing technology are extremely stressed by abrasion, impact and pressure. Service lives determine downtime and operating costs. Carbide laser hardfacing introduces tungsten carbides into a metallic matrix in a targeted manner, homogeneously distributed and undamaged – a significantly higher and more uniform wear protection than arc-based processes achieve with the same carbide selection.
Drill Bit in Mining Application
Before
Wear-related material removal at the cutting edges by abrasive minerals in continuous operation.
After
Carbide laser hardfacing with tungsten carbides – homogeneously embedded in the matrix, metallurgically bonded to the base material.
Result
Significantly extended service lives, fewer change-related downtimes and plannable maintenance intervals with simultaneously reduced material consumption of the protective layer.
Advantages of Laser Cladding in Industrial Use
Laser cladding combines properties that no other cladding process delivers in this combination: minimal dilution, precisely adjustable layer thicknesses from 0.15 mm and a near-net-shape layer build-up that often makes expensive post-processing unnecessary.
The focused energy input protects carbides from thermal destruction and enables reproducible hardfacing layers with homogeneous distribution. Via powder or wire filler and different spot sizes, the process is exactly matched to component, material and loading.
Very Low Dilution Below 2 Percent
The alloy composition of the deposit layer is almost completely preserved. Hardness loss and property reduction are significantly lower than with PTA or arc-based processes.
Minimal Distortion for Demanding Components
The local, controlled heat input leaves component geometry virtually unchanged. Even highly loaded or delicate components can be coated without costly straightening or preheating.
Carbide Retention through Focused Energy
Unlike arc-based processes, tungsten carbides and other hard phases are not thermally dissolved but embedded homogeneously and undamaged in the matrix.
Near-Net-Shape Layers from 0.15 mm
Layer thicknesses of 0.15 to 6 mm – in special cases up to 20 mm – can be precisely set. A 1 mm laser hardfacing layer frequently achieves the service life of a 3 to 5 mm thick flux-cored wire layer.
Reproducibility and Automation
High degree of automation, defined process windows and 2D/3D movement of optics and nozzle ensure consistent layer quality – even for complex geometries and in difficult positions.
Flexibly Deployable Powder- or Wire-Based
Powder-form fillers enable the finest carbide distribution; wire-based processes allow high material deposition rates. capilla feeds the wire centrically into the melt – precise and process-reliable.
When Is Laser Cladding the Right Choice?
Laser cladding is the right choice whenever dilution, distortion and carbide retention are decisive, or layer thicknesses need to be precisely set. Also where conventional processes reach their limits – such as with difficult-to-weld materials with high carbon content or with delicate components – the laser demonstrates its strength.
Typical application fields are demanding wear protection, near-net-shape coating of functional surfaces, repair of high-quality components and the additive build-up of complex geometries via laser 3D printing.
Laser cladding is particularly suitable for applications where:
very low dilution with the base material is required, for example to retain carbides or special alloys.
precise layer thicknesses from 0.15 mm and near-net-shape deposition are to save expensive post-processing.
components need to be coated with low heat input to avoid distortion and microstructural changes.
difficult-to-weld or considered non-weldable materials are to be processed without or with only minimal preheating.
complex geometries or spare parts need to be built up additively via laser 3D printing.
Near-Net-Shape Repair in Practice: Laser Cladding on a Fan Wheel
Fan wheels in the cement, recycling, power plant, chemical and bulk-material industries often convey highly abrasive fine dusts. Even minor material loss at the blade edges alters the flow geometry, reduces efficiency and increases energy consumption as well as wear of the entire plant. With near-net-shape laser cladding, CAPILLA precisely restores the original contour and protects heavily stressed areas with wear-optimised functional layers.
Fan Wheel with Flank Wear
Before
Fine-abrasive wear at the blade edges led to material loss, declining conveying performance and reduced fan efficiency. The altered flow geometry increased energy consumption, imbalance and maintenance effort.
After
Near-net-shape laser hardfacing on the worn blade edges. The specially developed functional layer bonds metallurgically with the base material and is applied precisely only where wear occurs.
Result
Restored flow geometry, significantly longer service life and permanently higher energy efficiency. Through targeted wear protection, material loss, maintenance effort and downtimes are sustainably reduced.
Laser Cladding Compared to Other Welding Processes
Classification and Characteristics of Laser Cladding
Laser cladding, also known as Laser Cladding or Laser Metal Deposition (LMD), sits at the top of industrial cladding processes. It combines very high energy density with precise spatial and temporal control of energy input. Powder or wire is specifically introduced into the weld pool created by the laser and metallurgically bonded to the base material.
Characteristic features are dilution of frequently below 2 percent, layer thicknesses from 0.15 mm and a near-net-shape layer build-up. Carbides remain undamaged by dispensing with a transferred arc and are homogeneously embedded in the matrix – a central advantage over PTA and arc-based processes.
Via 2D/3D movement of optics and nozzle, defined process windows and spot sizes, layer properties, contour accuracy and carbide distribution can be precisely controlled. In special cases, the process even enables the additive build-up of functional components via laser 3D printing.
Differences to PTA, TIG Cladding and Thermal Spraying
PTA Welding
PTA welding is the established industrial cladding alternative – lower equipment costs, with somewhat larger layer thicknesses and higher dilution. Laser cladding achieves more precise results with dilution below 2 percent and layer thicknesses from 0.15 mm, especially where distortion, carbide retention and near-net-shape are decisive.
TIG Cladding
TIG cladding offers manual flexibility and low equipment costs, but is primarily suitable for smaller components and repairs with manageable geometry. Laser cladding delivers the reproducibility and automation capability required in series coating of demanding components.
Thermal Spraying
Thermal spraying produces coatings without melting the base material – the layer adheres purely mechanically. Laser cladding creates a true metallurgical bond between layer and base material and is therefore significantly more load-bearing under impact, vibration and continuous loading.
Precise Technology. Clear Process. How We Work.
Every cladding project follows a structured workflow – from the initial component analysis to the inspected deposit layer. This produces reproducible results tailored to loading conditions, material and operating environment.
1. Component Analysis
In the first step, the geometry, material and operating conditions of the component are recorded. This includes the type of loading – such as wear, corrosion or thermal stress – as well as the required layer properties. On this basis, the appropriate welding process is selected and the process is designed.
2. Selection of Welding Consumable
Depending on requirements, different welding consumables and alloys are used, for example for wear protection, corrosion protection or heat resistance. The material selection is matched to the base material and the subsequent loading to achieve a permanently stable bond.
3. Component Preparation
Before cladding, the component is prepared accordingly. This includes cleaning the surface, removing contamination and, if necessary, mechanical preparation of the coating area. A clean surface is the foundation for a metallurgical bond and reproducible layer quality.
4. Cladding
Cladding is carried out with precisely set process parameters. Energy input, material feed and welding speed are controlled specifically to set layer thickness and penetration behaviour in a controlled manner. This produces homogeneous deposit layers with defined properties.
5. Quality Inspection
After cladding, the layer is mechanically post-processed as required, for example by turning or grinding, to achieve the required dimensional accuracy. Finally, the quality inspection of the weld seam and deposit layer is carried out before the component is returned to the customer.
Andreas Frische
Technical Management
Finding the Right Welding Process
Not sure which welding process is right for your application?
We support you in selecting and combining the right processes.
+49 5202 97790-54
Available from 07:45 - 16:30
a.frische@capilla-gmbh.de
Available from 07:45 - 16:30
Without the right welding consumable, there is no stable solution.
In laser cladding, the powder or wire filler, carbide content and alloy system determine the properties of the deposit layer – from wear resistance and hardness to corrosion and heat resistance.
capilla supplies powder and wire fillers for laser cladding, including carbide hardfacing materials with tungsten carbides and individually designed blends for wear protection and functional coating.
Automated Welding Processes at the capilla LCC
At the Laser Competence Centre (LCC), capilla brings together modern technologies for automated coating and manufacturing. Components are precisely built up, heat-treated and tailored to the application using laser-based processes. Layer thickness, material deposition and process parameters can be precisely controlled – even for complex geometries and series applications.
This produces coating and manufacturing solutions that go beyond conventional welding processes and cannot be realised with traditional approaches in this form.
Frequently Asked Questions about Laser Cladding
Laser cladding, internationally also known as Laser Cladding or Laser Metal Deposition (LMD), is a cladding process in which a focused laser beam locally melts the surface of a component. Simultaneously, a filler material – usually in powder form, alternatively as wire – is introduced into the emerging weld pool and metallurgically bonded to the base material.
Characteristic features are very low dilution with the base material, a near-net-shape layer build-up and the ability to precisely set layer thicknesses from 0.15 mm. The process is industrially used in coating and repair technology and also enables additive applications (Directed Energy Deposition, DED).
capilla deploys laser cladding for demanding wear protection, near-net-shape coating and repair of high-quality components.
In laser cladding, the component surface is locally melted by a laser beam. The filler material is introduced into the emerging weld pool – powder-based via nozzles with carrier gas, or wire-based via feed rollers. At capilla, wire feed occurs centrically into the melt for maximum process reliability.
Optics and nozzle move in defined 2D or 3D paths over the component, creating reproducible weld beads. Powder allows the finest carbide distribution and very thin layers; wire enables higher deposition rates. Carbides remain undamaged by dispensing with a transferred arc and are homogeneously embedded in the matrix.
capilla selects powder or wire process depending on component geometry, required layer and material system.
Laser cladding is industrially used wherever highest precision, low dilution, minimal distortion or carbide retention are required. Typical application fields are demanding wear protection on tools, drill bits, screws and rollers, near-net-shape coating of functional surfaces, and repair and restoration of high-quality components.
Additionally, the process enables additive applications: complex geometries or partial areas can be built up at short notice with equivalent function via laser 3D printing – for example as a spare part when delivery times are long, or to realise geometries that would not be conventionally manufacturable.
capilla deploys laser cladding individually configured for component geometry, loading and service life requirement.
The central advantages of laser cladding over PTA and arc-based processes are very low dilution (frequently below 2 percent), precise near-net-shape deposition with layer thicknesses from 0.15 mm and the retention of embedded carbides. Tungsten carbides are not dissolved by high arc temperatures but homogeneously embedded in the matrix – resulting in significantly higher and more uniform wear protection.
Added to this are minimal distortion through targeted heat input, high reproducibility and automation capability, as well as the ability to process difficult-to-weld materials without or with only minimal preheating. With comparable service lives, a 1 mm laser layer often suffices where PTA or flux-cored wire requires 3 to 5 mm.
capilla supplies powder and wire fillers matched to laser processes that make the process advantages fully usable.
Laser cladding enables layer thicknesses of approximately 0.15 to 6 mm. In special cases, layer thicknesses up to approximately 20 mm are also achievable. Layer widths typically range from 0.5 to 10 mm depending on spot size and nozzle geometry. This means the process covers an exceptionally broad application spectrum – from finest functional layers to more massive wear protection deposits.
In direct comparison, very thin laser layers of 0.25 to 0.50 mm already achieve the hardness and wear properties that conventional processes only deliver after several passes and 3 to 5 mm of layer thickness. This results in lower material consumption, less distortion and an overall more efficient coating process.
capilla designs layer thickness and layer width individually to match loading and component geometry.
Laser cladding processes an exceptionally broad spectrum of materials: nickel-, cobalt- and iron-based hard alloys, corrosion-resistant stainless steels, wear protection alloys with tungsten carbides, chromium carbides or other hard phases, as well as special materials. Even materials with high carbon content that are often considered difficult to weld with conventional processes can in many cases be processed without or with only minimal preheating.
Particularly relevant is the retention of embedded carbides: tungsten carbides are not dissolved by the focused, controlled energy input but homogeneously and undamaged embedded in the matrix. The process window reliably prevents carbides from sinking due to density differences or segregating.
capilla selects the material and carbide system specifically according to bulk material specification, loading and service life requirement.
Dilution with the base material in laser cladding is typically below 2 percent. This means: almost the entire alloy composition of the filler material is preserved in the deposit layer. Hardness loss and property reduction through mixing are considerably lower than with PTA (typically 5 to 15 percent dilution) or conventional arc processes (often 20 percent and more).
The low dilution is a direct consequence of the focused and controlled energy input of the laser. The defined process window allows the base material to melt only locally and to a shallow depth – just enough for a genuine metallurgical bond.
capilla uses the low dilution specifically to provide carbides, special alloys and defined layer properties reproducibly.
Laser cladding is particularly well suited for the repair and restoration of worn or damaged components. Through the local heat input, the rest of the component remains thermally virtually unaffected – a decisive advantage over large-area thermal loading with conventional processes. Distortion and microstructural changes are minimised.
Typical repairs are restoration of tool edges, filling of worn functional surfaces, build-up of worn screw flanks or the targeted sealing of cracks on high-quality components. In urgent cases or when spare parts are unavailable, complex geometries can also be produced at short notice with equivalent function via laser 3D printing.
capilla supports the economical repair of high-quality components through individually designed laser deposition.
Yes, laser cladding enables a particularly precise, near-net-shape layer build-up. Through the 2D and 3D movement of optics and nozzle, defined weld paths are created that can be exactly adapted to the required geometry. Functional layers can often be applied already nearly in final contour, so that costly post-processing such as diamond grinding is eliminated or greatly reduced.
In the area of additive manufacturing, laser cladding is an established variant of Directed Energy Deposition (DED). This enables complex geometries, functional areas or entire components to be built up additively – including where conventional manufacturing reaches its limits or spare parts are needed at short notice.
capilla deploys near-net-shape deposition and additive applications specifically to reduce post-processing and delivery times.
Laser cladding is the better choice as soon as a metallurgical bond between layer and base material is required. Thermal spraying produces layers that adhere purely mechanically – sufficient for many applications, but under impact, vibration or continuous loading not as load-bearing as metallurgically bonded layers. Laser layers are fully metallurgically bonded.
Against flux-cored wire cladding, the laser demonstrates its strengths when dilution and distortion are to be minimised, carbides are to be retained or very thin layers are required. A 1 mm laser hardfacing layer frequently achieves the service life of a 3 to 5 mm flux-cored wire layer from the same alloy system – with significantly lower weight, material usage and component distortion.
capilla selects the cladding process – laser, PTA, MIG/MAG or thermal spraying – according to the specific requirements for layer, component and loading.