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<strong>AMMJ</strong> Laser Cladding 10 REPAIR OF COMPRESSOR SHAFT The compressor shaft is made of martensitic stainless steel AISI 410 (DIN 1.4006 / X12Cr13). Near the end of the shaft an area with an axial length of 70 mm was worn off. The total length of the shaft was about 3,7 m and the weight was about 1 ton. For laser cladding, stainless steel powder AISI 316L is used as feedstock. A coating with a total thickness of 2 mm is required. Since it is not possible to obtain a coating with a thickness of 2 mm after a single pass, multiple layers are applied on top of each other. The typical maximal layer thickness for a single pass is 1-1,2 mm. After laser cladding about 0,2 mm of the thickness needs to be removed to obtain a smooth surface. PRELIMINARY TESTS Before treating the shaft, experiments are performed on a small bar to evaluate the quality of the coating in terms of absence of cracking, the degree of deformation of and the bonding to the substrate. To evaluate the deformation behaviour, a bar with a diameter of 30 mm and length of 700 mm was cladded at both ends over a length of 20 mm. The results of a run-out were satisfactory and showed a deformation of only 0,02-0,04 mm. The cross section of the coating near the beginning is shown in Figure 3. No cracks in the coating or in the martensitic stainless steel substrate are present. Due to the presence of key-seatings, which did not need to be treated, copper inserts were placed at these positions to prevent these areas being damaged by the laser beam. The stainless steel 316L material does not adhere to the copper and the copper insert can be easily removed after laser cladding. LASER CLADDING OF SHAFT The same laser cladding parameters as used in the preliminary tests were applied during laser cladding of the shafts. The experimental setup is shown in Figure 4. The presence of the copper insert at the key-seatings is visible at the left image of Figure 4. Two layers of stainless steel are applied on top of each other. The shafts are machined afterwards and the repair was positively evaluated: adequate thickness and good bonding of coating to substrate, minimal deformation induced by laser cladding, and no porosity in coating. Figure 4 Setup used for laser cladding of compressor shafts Figure 2 Laser cladding setup used in the study. Figure 3 Cross section of AISI 316L on a AISI 410 stainless steel substrate Vol 24 No 1
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