Machine regeneration using TIG or MIG/MAG methods often results in deformations, material weakening, and the need for further machining. Laser cladding allows worn components to regain factory strength, and even exceed it - without destructive impact on material structure. Discover what laser cladding is, where it works best, and what its greatest advantages are.
What is laser cladding?
In short: it's a process in which a concentrated laser beam melts additional material (in powder or wire form), creating a metallurgical bond with the component surface. This rebuilds existing parts layer by layer. The result? A metallurgical, dense connection with minimal porosity. A coating that becomes an integral part of the detail, not just an additional "patch".
Cladding vs. laser welding - differences
The purpose of laser welding is to join two or more separate elements into one whole. Here, the weld matters, which holds all elements together.
Laser cladding doesn't join elements together. Its purpose is to improve an already existing component surface. Cladding is about adding a new layer to one element, so as to:
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rebuild it, restoring it to factory dimensions,
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strengthen it, giving it new properties - e.g., hardness, corrosion resistance, wear resistance.
What materials can be laser clad?
This technology handles a wide range of materials: from steel (stainless, carbon, galvanized), through nickel, cobalt and titanium alloys, to aluminum alloys or harder-to-machine copper alloys. Moreover, it allows combining different alloys, creating unique, graded structures with properties unavailable in homogeneous material.
How does laser cladding technology work?
It's a process that boils down to four steps:
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Targeting: A concentrated laser beam is directed at the surface of the repaired component. Cladding is extremely precise – we're talking about focusing energy at a point with a diameter of fractions of millimeters.
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Melting: The laser creates a small, fully controlled "pool" of liquid metal on the metal surface in a fraction of a second.
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Adding: Precisely into this welding pool, at the same moment, additional material is fed – a stream of metallic powder or thin wire.
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Joining: The additional material immediately mixes with the liquid substrate metal. When the laser beam moves further, this mixture instantly solidifies, creating a new, perfectly smooth and uniform layer.
The entire process is repeated until the original shape and dimensions of the component are restored. The entire advantage of this technology stems from two facts:
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It's a metallurgical connection. The new layer becomes an inseparable part of the component, creating a uniform structure with it. Thanks to this, the coating is extremely resistant to wear and cracking.
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It's a "cold" process. Laser energy is delivered so quickly and in such a small point that the rest of the detail doesn't have time to heat up. This eliminates the problem of deformations and internal stresses, which is the bane of traditional welding methods.
As a result, in a very short time it's possible to obtain a repaired part with precision unattainable by human hand, without quality-destroying side effects.
Technical parameters and impact on quality
In the laser cladding process, you can regulate parameters to achieve the effect you need. These parameters are:
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Laser power and weld geometry. You control the power and depth to which material penetrates into the substrate. You control beam focusing, deciding on the width of the clad track. You can create thin protective coatings and rebuild larger defects.
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Process speed. TIG, MIG/MAG can be slow. Laser works instantly. Advanced systems, like those using EHLA technique, apply material at speeds of several hundred meters per minute. This is not a typo.
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Heat Affected Zone (HAZ). In TIG, MIG/MAG welding, heat causes stresses, deformations and structure weakening. Laser works differently. It delivers enormous energy in a very small point and short time. Before the rest of the component has time to heat up, the process is already finished. The effect? Minimal Heat Affected Zone (HAZ). In practice, this means the detail doesn't lose its original mechanical properties and often requires no additional machining.
What are the material feeding methods?
You have two paths:
Wire cladding – precision and cost control
This is the choice for those who prioritize economic efficiency. Wire is cheaper than powder, and the process generates negligible material losses. You gain full control over the chemical composition of the deposit, which guarantees repeatable results.
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Advantages: lower material cost, minimal losses, consistent coating properties.
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Disadvantages: smaller selection of available materials, process is slower than when using powder.
Powder cladding – speed and versatility
When time matters and you need non-standard properties, additional material in powder form opens completely new possibilities. The available range of materials is enormous – from various metal alloys to ceramics.
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Advantages: huge selection of materials, higher efficiency and process speed.
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Disadvantages: higher cost of powders, necessity of using dust extraction systems.
Where does laser cladding work best?
This technology is not a universal solution. Its strength is visible where three key factors determine the profitability of the entire project. These factors are: precision, durability and time.
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Automotive industry and mechanical engineering: Regeneration of shafts, injection molds or engine components. Instead of buying new ones, you restore their factory strength for a fraction of the price.
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Aviation and aerospace: Repair and strengthening of aircraft engine turbine blades. Laser allows working with light, advanced alloys that must withstand extreme temperatures and loads.
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Energy and petrochemicals: Rebuilding components of wind and gas turbines, shafts or bearings. Creating coatings resistant to wear and corrosion in the most demanding environments.
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Tool industry: Regeneration of worn molds, dies and cutting tools. Instead of throwing away expensive tools, you extend their life several times over.
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Medicine: Repair and creation of implants and surgical instruments. Laser precision guarantees perfectly smooth, hygienic and durable connections.
Laser technology solves real problems in the most demanding branches of industry. If you want to learn how to translate these possibilities into concrete numbers, read: Read: When to invest in a laser welder and how to calculate return on investment.
Key advantages of laser cladding - does it beat TIG, MIG/MAG?
1. Precision
The laser beam focuses energy at a point with a diameter of fractions of a millimeter. The Heat Affected Zone (HAZ) is minimal. In practice, this means no deformations and material stresses. The component after regeneration maintains its dimensions and mechanical properties. No more expensive corrective machining.
2. Speed
The process is significantly faster than conventional methods. Short cycle reduces machine downtime and accelerates order fulfillment. Advanced techniques, like EHLA (Ultra-High-Speed LMD), achieve cladding speeds of several hundred meters per minute.
3. Durability
Laser-clad coatings are dense, uniform and free from porosity. Metallurgical bonding with the substrate ensures resistance to cracking, wear and corrosion, radically extending part life.
4. Automation
The process can be fully automated and integrated with industrial robots and CNC systems. This guarantees identical quality for every detail – something unattainable with manual work, especially in series production.
Full utilization of automation potential requires new skills from operators, but team implementation doesn't have to be a barrier. See what professional laser welding training looks like and how to efficiently introduce this technology to your company.
Laser cladding - what you need to know before investing? Limitations and costs
Precision? Speed? Durability? There's also the other side of the coin.
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High investment costs: Purchasing complete laser systems (source, head, control) is an expense significantly exceeding the purchase of a MIG/TIG welder. This is an investment that must have solid business justification.
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Requirements and operation: Class 4 laser requires rigorous safety procedures and trained operators.
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Sensitivity to preparation: Laser is merciless for inaccuracies. It requires a clean surface and precise detail positioning. It doesn't tolerate large gaps or irregularities.
High investment costs may encourage searching for cheaper alternatives on the market. It's worth remembering that low price often goes hand in hand with hidden compromises that can affect reliability and precision. Before making a decision, check what traps are hidden in cheap laser welders.
Summary - is laser cladding right for your company?
Laser cladding is not a technology for every company. If you produce simple components where millimeter deviations don't matter, existing methods may still be sufficient. But if you compete on quality and precision, this technology becomes a necessity. Do you see potential but aren't sure if laser cladding will work in your specific case and if the investment will pay off? Let's talk about your needs during a free consultation, and we'll help assess the profitability of this technology for your company.