EHLA = State of the Art
Application & Industries
The powerful ACunity EHLA system offers standard and customized solutions for almost all industries and sectors. The areas of application are expanding rapidly.
Offshore Industry & Shipbuilding
Many parts and components of drilling rigs, ship cranes, machinery and equipment are exposed to the harsh conditions of the sea for years and therefore need to be regularly protected and repaired. EHLA technology is also suitable for wear and corrosion protection on parts of marine machinery. It is widely used for products such as marine diesel engines, gas turbines, steam turbines, propellers and ship hulls. The laser coating is dense, has high corrosion resistance and provides adequate protection.
Surface repair of drilling tools, hydraulic cylinders, balance shafts, drive shafts, impellers, turbines ...
Mining
Machines for coal mining have to work in dusty, wet mine environments and withstand long periods of use and high loads. Corrosion and wear shorten their service life. Currently, hydraulic support units often require complex maintenance, which is time-consuming as the components have to be dismantled underground.
The trend towards automation in mining, which eliminates the need for manual intervention in underground operations, places higher demands on the performance and service life of hydraulic support units. This is where high-quality, environmentally friendly and cost-effective production technologies such as EHLA come into play. They help companies to improve their competitiveness on the market and achieve long-term growth.
Wear-resistant surfaces for hydraulic cylinder rods, piston rods, shafts, axles, gearboxes and coal conveyor systems ...
Tool & Mold Making
The service life of a mold depends on how well it can withstand extreme mechanical stress. Once worn or damaged, it is difficult to repair. EHLA technology can be used for the precision repair of high-quality molds, especially for small defects. The powder materials can be produced in different ratios depending on the application conditions and performance requirements of the mold. Compared to traditional arc welding technology, the advantages are: less heat input, less thermal stress on the substrate and less residual stress in the repair area.
Surface repair and modification for punches, cylinders, inner and outer walls of cylinders
E-Mobility
Automotive brake discs are made of gray cast iron with a laminated graphite phase. This material can withstand the high temperatures generated during braking and is relatively inexpensive. However, it wears out quickly, releases harmful fine particles and corrodes.
With the environmentally friendly EHLA process, one or more homogeneous, harder layers of stainless steel and other powder materials can be applied to protect the discs, make them more durable and prevent abrasion. Thanks to the significantly faster process speed of EHLA compared to conventional methods, the base material is exposed to the heat of the laser for a much shorter time, which enables new material combinations and prevents carbon elements from detaching from the brake disc and contaminating the new surface layer. The layer thickness is variable; a thin layer between 25 and 250 μm can be applied, which saves on powder materials.
The braking behavior of electric vehicles differs significantly from that of gasoline-powered cars. Regenerative braking systems in electric cars lead to less wear on the brake discs than in petrol-powered cars. However, the problem of corrosion is greater. Depending on the type of vehicle, the coating material and the number of layers for the brake discs can vary.
Surface coatings for brake discs
Agriculture
Agricultural machinery is often used under poor conditions and with high intensity. Gearbox and shaft components are the parts that are most susceptible to wear, cracking and corrosion.
Laser metal deposition is an important technique for on-site repairs to restore worn machine parts to their original size with minimal deformation, rapid cooling and high precision. Studies have also shown that the impact resistance, hardness and wear resistance of the treated parts are improved. On-site repair using LMD fills scratches and restores the surface profile of the shaft, bearing, etc.
With specially selected powder mixtures, a higher degree of hardness can be achieved for the cutting areas of the tools. The coating technology helps to improve the efficiency of machines and equipment and reduce production costs.
Repair of gear and shaft components; surface hardening for movable knives, fixing knives, picking plates, crushing knives, etc.
Construction Machinery
Long-term use of construction machinery under extreme conditions can easily lead to damage to equipment components. The amount of work required for regular maintenance and repairs is high and costly. At present, processes such as electroplating or thermal spraying are still used for surface treatment, which are associated to varying degrees with defects such as soiling, low adhesive strength and durability.
With the EHLA process, functional parts of construction machinery can be better and more sustainably protected against corrosion and wear with a wear-resistant coating. Remanufacturing repairs extend the service life of these machines and ensure cost efficiency in their use. EHLA has advanced features: precise energy control, limited heat input and minimized heat-affected zone of the workpiece.
Suitable for surface repair and hardening of wheels, gears, piston rods, pins, shafts etc. on lifting, earthmoving, transportation, concrete and railroad maintenance machines
Paper Production & Printing
Large rollers in the paper industry must meet high requirements in terms of surface quality and dimensional accuracy. They are expensive to manufacture. With the EHLA process, the surface of these rolls can be processed with high precision. They are thus ready for use for longer.
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