Innovations in high power laser cladding: the COAXquattro and Flextrack systems for enhanced manufacturing efficiency

Toma Laura - Fraunhofer IWS Dresden (Germany)

This paper discusses groundbreaking advancements in high power laser cladding technology, primarily focusing on two innovative systems: COAXquattro and Flextrack. The COAXquattro system operates with laser powers of up to 20 kW and incorporates four coaxial wires and four powder channels, enabling simultaneous feeding into a single melt pool. This design allows for independent control of feed rates, facilitating in-situ alloying and graded coatings by real-time chemical composition adjustment of the deposition material.

The paper presents various use cases showcasing high productivity laser cladding processes for functional coatings, including sliding bearings and wear-resistant surfaces, which enhance component durability. Additionally, large-scale additive manufacturing applications using aerospace aluminum alloys and stainless steel 316L are discussed, highlighting their importance in producing lightweight, high-strength components for critical industries. Experimental results and case studies illustrate substantial improvements in manufacturing efficiency and adaptability to complex geometries.

On the other hand, the Flextrack system introduces wide-field laser cladding with adjustable deposition track width. Utilizing advanced 1D laser scanning technology, Flextrack accommodates rectangular spots up to 45 mm wide, enabling cladding tracks between 10 mm and 45 mm during motion. This system offers various scanning frequencies from 1 Hz to 300 Hz to evaluate their effects on cladding results. Furthermore, an integrated camera system monitors the melt pool’s temperature and size, providing insights into laser power distribution and providing options for process monitoring and control. These innovations significantly enhance the flexibility of laser cladding, especially for applications with varying part geometriessuch as wear-resistant coatings on conveyor screws and tailored patches for agricultural tools.