Abstract Laser cladding is a surface enhancement technique that involves applying a cladding material onto the surface of a substrate and melting it with a high-energy-density laser beam. This process creates a metallurgical bond between the cladding layer and the thin surface layer of the substrate, resulting in a strong, durable coating. After laser cladding, the surface hardness typically exceeds HRC 50, and in some cases, can reach up to HRC 70.
In response to the specific demands of the laser cladding repair industry, Hualing Superhard has developed a non-metallic adhesive polycrystalline cubic boron nitride tool material—BN-S20. This grade is specifically designed to meet the processing characteristics of cladding materials and the microstructure of alloys after laser remelting heat treatment. It offers high hardness combined with good impact toughness, making it ideal for use on surfaces that may be uneven or contain hard spots.
Laser cladding materials commonly used include nickel-based, cobalt-based, iron-based alloys, and tungsten carbide composites, with nickel-based materials being the most widely applied. However, due to their high hardness and elevated cutting temperatures, these materials pose challenges for traditional tools. This makes it essential for the tools to possess excellent heat resistance, wear resistance, and impact toughness, especially when dealing with irregular cladding surfaces.
The BN-S20 grade tool not only outperforms cemented carbide and ceramic tools in terms of hardness but also exhibits superior toughness compared to ceramic tools. It is particularly effective for long-term machining of large roller-type parts after laser cladding, as it can withstand the impact from hard spots or surface imperfections.
When used for turning operations on shafts and disc components after laser cladding, the BN-S20 tool eliminates the need for grinding (car grinding), significantly improving processing efficiency. The surface roughness achieved is typically between Ra 0.4 and Ra 0.6, which is comparable to the finish produced by conventional grinding machines. This tool is widely used in the repair of various shaft-type components, including metallurgical rolls, air compressor rotors, large crankshafts, pump shafts, and hydraulic support column pillars.
One of the key advantages of the BN-S20 grade is its ability to finish laser-clad workpieces in a single step, reducing the number of transfers and minimizing the risk of quality issues such as bumps caused by handling. Additionally, the surface roughness of the entire workpiece is more uniform than that achieved by traditional grinding methods, and it avoids the problem of grinding burn. Compared to grinding, using BN-S20 can reduce costs by approximately 40%.
As modern manufacturing technology continues to evolve, new and advanced tool materials are increasingly being integrated into CNC machining systems. Reliable and high-performance tools like BN-S20 will play a crucial role in expanding the application and development of laser cladding technology in various industrial sectors.
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