F068: Advanced Laser Manufacturing Applications

Fusion Technologies (division of Har-Bach) manufactures and supplies equipment and consumables to apply wear resistant overlay on steel surfaces with a strong focus on metal matrix composites.

Durability and wear resistance are paramount in drilling, mining, construction and agriculture. Hard surfacing technologies play a crucial role in extending the lifespan of critical components. Among the leading techniques, plasma transfer arc (PTAW) welding and laser cladding stand out for their ability to apply protective coatings with precision and efficiency.

This presentation will explore the key differences between PTAW and laser cladding technologies, their use to produce high wear surfaces with metal matrix composites such as tungsten carbides powders and diamonds

Femtosecond laser surface processing has successfully transitioned from the laboratory to large-scale, robotic implementation for industrial components. This leap, driven by the Robo-CLASP project, combines high-power 300W commercial femtosecond lasers, novel hollow-core fiber for beam delivery, and advanced in-situ process monitoring. The integrated robotic system can process components on a scale of tens of meters at speeds competitive with traditional methods like grit blasting and chemical stripping.

This presentation will discuss the resulting mechanical bond strength, thermal properties, and laser quality. The crucial role of in-situ monitoring and feed-forward control in maintaining focus and ensuring stability on complex geometries will be highlighted. Finally, data on process rate and cost will demonstrate the technology's current viability for applications like coating removal and surface functionalization, outlining its potential to shape future advanced laser system development and applications.