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Generation of wear resistant high performance layers with laser radiation

A completely new rotary swaged steel camshaft was developed. The rotary swaging technology was combined with a pressing technique to achieve a non-rotationally symmetrical camshaft. The achieved weight reduction of about 50% should result in a reduction in the consumption of gasoline. A completely new technique to alloy 3 dimensional part like a camshaft using a 2-stage process (first, application of a carbon layer with a spraying technique and second, remelting of the layer with laser radiation) was developed. Ledeburitic layers with a thickness of 0.4 mm after finish-grinding and a hardness of 650 +/- 50 HV were achieved.

An aluminium brake disc was produced that was approximately 30 to 40% lighter that current cast iron brake discs (resulting in a reduction in the consumption of gasoline). A new technique to alloy a brake disc using a 2-stage process (first, application of a plasma sprayed layer of 75Mo 4.25Cr 0.8B 1Fe 0.2C Ni and second, remelting of the layer with laser radiation) was developed. Alloying of aluminium brake discs using carbon dioxide-laser radiation has been achieved, delivering alloyed layers of approximately 0.5 mm thickness and a hardness of 200-250 HV with a deformation less than 0.2 mm. Concerning laser alloyed plasma sprayed discs, both wear and crack resistance are far better that those from plasma sprayed layers only, but at present remain lower than cast iron brake discs performances.

High molybdenum-content layers for extruders were developed, containing 41-63 mass% molybdenum. The wear performance of the new laser clad layers is up to 60% better than the plasma transferred arc (PTA) layers used at the moment in production. The cladding technique for extruders was developed, especially the processing technique to clad tracks with a width of 12 mm and a thickness of 1 mm in one pass.

Reported by

Fraunhofer Institut für Lasertechnik ILT
Steinbachstraße 15
52074 Aachen
Germany
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