REFERENCES AND REFERENCE WORK
Duroc Laser Coating offers expert repair of steel surfaces and new production of customer-unique surface-treated components for small and large series. Metal construction using laser technology meets the requirements for extreme surface and functional properties regarding friction, corrosion, wear, etc.
Here we present a selection of our reference works.
Feed roller segment
Nordic Quick Systems
Press hardening tool
Feed roller segment - Nordic Quick Systems
Duroc Laser Coating has helped Nordic Quick Systems with laser cladding of their unique feed roller solution for sawmills.
The replaceable segments, which in themselves mean a significant reduction in work in the event of maintenance stoppages, become even better when its surfaces are reinforced with DUROC TiC42 as the service life increases markedly. Fantastic news for all the world’s sawmills!
DUROC TiC42 is an additive material that contains titanium carbides, which create extreme abrasion resistance. DUROC TiC42 can be used for both cladding and impregnation depending on which surface properties are sought in addition to the extreme abrasion resistance.
Feed rollers - SCA Timber
The grooves of the roller are rebuilt with laser cladding
“In the autumn of 2007, we inserted a feed roller with laser-welded grooves into the feed in saw line 2. It has now been in operation for almost four years, and I would think that it will run for the same amount of time,” says David Engberg, maintenance manager at SCA Timber in Munksund. “The feed rollers that are delivered with new saw lines today have thermally sprayed grooves. These are completely worn out after two years.”
The task of the feed roller is to propel the log along the saw line. It has a ribbed surface layer to get a good grip on the log. If the roller and grip do not work well, the log slips and gets stuck or there is a fault in the feed to the dividing saw blade with serious quality disturbances as a result.
The surface layer of the roller is rebuilt using a laser
The grooves of the roller are rebuilt with laser cladding. The welded material is a durable tool steel mixed with hard, wear resistant carbide particles.
About SCA Munksund
SCA Munksund delivers sawn and planed pine. The annual capacity amounts to 440,000 m3 of sawn timber. Keeping production as trouble-free as possible is, of course, of great importance for both product quality and profitability.
Mold steels - Olofsfors
Significant service life increases with laser impregnation on mold steels
Olofsfors, which manufactures tracks for forest machines, previously had problems with the service life of the mold steel in their most demanding tools.
“The great stresses to which our mold steel is subjected to during the pressing of details previously meant that the steel had to be replaced at frequent intervals. Still, we could not be completely sure that the right tolerances were maintained between the exchanges,” says Caisa Johansson, production technician at Olofsfors AB. “To achieve the desired service life and reduced spare part costs, we turned to Duroc Laser Coating to test laser impregnation on our molded parts.”
“In collaboration with Duroc Laser Coating and a molded parts manufacturer, a concept was developed by which the molded parts are hardened during manufacture and then surface-reinforced with laser impregnation.”
“The result was that we could use our molded parts twice as long without replacing them with new steels, which of course saves both time and money. This means that we avoid costly replacements of molded parts unnecessarily and that we can plan replacements in a much safer way when it suits our production. We have been given the opportunity to work proactively instead of reactively, which is very beneficial for us,” Johansson concludes.
Press hardening tool - Gestamp Hardtech
Press hardening tools increase their service life with laser impregnation
“The first tool that was laser impregnated has to date completed 380,000 strokes,” says Age Risberg at Gestamp HardTech in Luleå. A tool without impregnation normally does about 20,000 strokes before it must undergo reconditioning.
A growing trend in the industry is thermoforming technology, so called press hardening. The method means that high-strength steel is heated up to over 900 degrees Celsius and then shaped and cooled at the same time in press hardening tools.
The component manufacturer Gestamp HardTech is the pioneer behind press hardening technology. The company supplies safety details to the automotive industry. In 2005, Duroc began a collaboration with Gestamp for laser impregnation of wear-exposed parts in press hardening tools.
Thin high-strength steel places new demands on the manufacturing processes
The background to thermoforming technology is, among other things, the increased environmental requirements. Car details will be lighter and thus more energy-efficient at the same time as they will be harder and safer. The use of thin, high-strength steel is increasing, which places new demands on the manufacturing processes.
In Olofström, Volvo Cars is preparing for an upcoming technology change, even though no formal decisions have yet been made. The method has also become common in other industries, where parts with high strength, low weight, and advanced geometries must be formed.
Valve discs - Parker Hannifin
Lead-free valve discs with laser clading
Parker Hannifin has used bronze in a valve disc for several years in the manufacture of hydraulic machines, such as pumps and motors. With changed requirements regarding increased performance and elimination of lead in the bronze metal, Parker began to look around for new solutions.
Alternatives in the form of rolling, thermal spraying, thin film coating and laser surface treatment were evaluated through studies of the machine parts’ function and performance as well as the efficiency of the process.
Duroc Laser Coating’s laser cladding proved to be able to offer a completely lead-free laser bronze with superior performance compared to other methods. It is also a flexible solution that enables production adapted to demand and shortened lead times.
“Duroc Laser Coating’s solution has rationalized our manufacturing process and gives us an improved overall economy,” explains Mats Karlsson, purchasing manager at Parker Hannifin in Trollhättan.
Wheel spindles - Caterpillar
Wheel spindles that are renovated with lasers last longer than new ones
“Laser cladding of a wheel spindle costs maybe a fifth compared to buying a new one,” explains Lars Almqvist, who together with Kalle Thyni is responsible for the maintenance of the Caterpillar trucks at the Aitik mine. “But above all, it holds up so well. You do not have to worry about costly warehouse breakdowns. Traditional overlay welding is not an option.”
“There is no alternative method to laser cladding,” Almqvist explains. “The heat beam is small and accurate and provides high precision, which means that you can weld without affecting the surrounding base material. With traditional overlay welding, the heat impact becomes so deep that you risk a fracture indication further down or in the weld itself.”
The Aitik mine outside Gällivare is one of Europe’s largest copper mines. Every year 17-19 million metric tons of ore and 25 million metric tons of waste rock are mined here. Duroc does maintenance work using laser cladding, mainly for preventive purposes, but even more urgent issues sometimes occur.
Through a full-service agreement, PonCat handles the maintenance of the mining trucks for Boliden Mineral. Maintenance is mainly for preventive purposes. According to a rolling plan, the components are lifted out for renovation after a certain number of hours.
“We work exclusively for preventive purposes. If a component were to break down, the repair cost would be almost double,” Almqvist explains.
Laser cladding lasts twice as long as the original spindle
The fleet of Caterpillar trucks in the Aitik mine consists of six 789s and seventeen 793s. In 1995, Duroc laser renovated the first wheel spindles on the CAT 789. After eleven years, the spindles have not yet needed to be repaired or replaced. To compare with the original spindle that lasted for six years. In 2006, the newer 793 truck model was also renovated.