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 REPAIR and CLADDING

When operating any type of mechanical equipment with moving parts, repairing or rebuilding worn metal components is part of everyday life. Repairing worn components typically saves dollars over purchasing new ones. When a worn part is rebuilt, the potential also exists to repair that component in such a manner that it will have a longer wear life than a new part.

Directed Energy Deposition (DED) has a number of key benefits over other repair techniques that make it possible to repair some parts that were previously considered un-repairable. Using other techniques, either the part could not physically be repaired, or it was not economically feasible to perform the repair.
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Some of the benefits of DED over other repair techniques are:
  • Metallurgical Bond versus Mechanical Bond
    The DED process creates a metallurgical bond which is much stronger than the mechanical bond created using spray welding or plating techniques.
  • Low, Controlled Heat Input
    The DED process creates very low and controllable heat input with minimal dilution and heat effect zones.
  • Minimal Stress and Distortion Created by Deposits
  • Rapid Cooling Rates
  • Cost Effective for Repairs and Manufacturing​

The key benefits of DED over other techniques are that it 1) creates a stronger bond and 2) inputs less heat to the part being repaired. The benefits of the stronger bond are obvious. The lower heat input means less distortion of the part during the repair process. These two benefits make the DED process unique.

Common Applications.

REPAIR
  • Blades/Airfoils
  • Blisks
  • Drums
  • Labyrinth Seals
  • Tooling Marks/Gouges
  • Shaft Tapers, Threads, and Bearing Surfaces
CLADDING
  • Shaft Tapers, Threads, and Bearing Surfaces
  • Add Wear Material to local diameters
  • Build up of Flanges to standard Pipe/Tube
  • Coupler Surfaces

Case Studies.

Directed Energy Deposition (DED) Repair Taper
Part as repaired with Thermal Spray
Directed Energy Deposition (DED) Repair Taper
4ft Part
Directed Energy Deposition (DED) Repair Taper
Repaired Surface

​4340 
​
Atomizer Shaft 

  • This 4340 Atomizer Shaft is a high speed (8800rpm) precision shaft used in “Flue Gas Desulfurization” (FGD) scrubber systems.
  • Shafts were previously repaired by a Spray Process featuring a “Mechanical Bond.” 
  • Laser Repair utilizes a “Metallurgical Bond” that generates a high quality permanent repair
  • Repair includes deposition of 420L SS to tapered fit section and seal surface
Directed Energy Deposition (DED) Clad
Cladding 4 ft diameter surface
Directed Energy Deposition (DED) Clad
Final Part - 4 ft diameter
Directed Energy Deposition (DED) Clad
Cladding 20" OD
Directed Energy Deposition (DED) Clad
Final Part - 20" OD

​Bearing Surfaces

  • Replaces tool steel parts with long lead time
  • Cladding steel with CoCr material on wear surfaces only
  • Improved part life on average by 2X-3X conventional part lifetime
Directed Energy Deposition (DED) ID Head Clad
ID Deposition
Directed Energy Deposition (DED) ID Head Clad
ID in vertical position
Directed Energy Deposition (DED) ID Head
ID Head Configurations

ID Surface Repair

  • Repair or add wear resistive materials to ID surfaces
  • ID head capabable of depositing in 2.25" (57mm) ID cylinders, up to 24" (609 mm) deep
  • Multiple orientations possible
Directed Energy Deposition (DED) Shaft Repair
Damaged Shaft
Directed Energy Deposition (DED) Shaft Repair
Laser Repaired Shaft and Thread
Directed Energy Deposition (DED) Shaft Repair
Final Machined

SS Atomizer Shaft

  • Atomizer shaft operates at 13,000 RPM
  • Seal area of shaft was worn and repaired with 420L SS
  • Nut and threads were repaired using 316L SS
Directed Energy Deposition (DED) Repair
Undersized Forging
Directed Energy Deposition (DED) Repair
Laser Repair of outer lip
Directed Energy Deposition (DED) Repair
Laser Repaired Part
Directed Energy Deposition (DED) Repair
Final Machined Ti-6Al-4V Driver Plate

Ti-6Al-4V Driver Plate

  • Forging delivered undersized (no outer lip)
  • Laser deposited the outer lip oversized and final machined to print
​Copyright © 2021 RPM Innovations, Inc.
​All Rights Reserved.

RPM Innovations, Inc.
500 Turbine Drive
Rapid City,SD 57703
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​PHONE: 1-855-554-7764
EMAIL: sales@rpm-innovations.com
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  • Home
  • Our Technology
    • Freeform
    • Repair and Cladding
  • MFG Services
  • Laser Systems
    • 557XR
    • 535XR
    • 222XR
  • Company
    • News and Related Links
  • Videos
  • Careers
  • Contact Us