From an opening diameter of 30 mm, Pallas can coat the entire range of internal contour processing up to a depth of 500 mm without pores using the iClad internal processing optics.

To process the defective surface, a narrowly focused laser beam melts a thin edge layer of the base material and the powder injected via a nozzle. In the resulting melt pool, the materials combine metallurgically to form a dense layer with minimal mixing. This allows CNC or robot-controlled layers and geometries in thicknesses from 0.1 mm to several millimetres to be welded on even in hard-to-reach areas. When processing internal contours, the immersion depth of conventional processing optics is severely limited by small aperture diameters. The special optics make it possible to correct the faulty design with a locally limited heat input. The iClad with a 35 mm processing head is used for this. The special optics also save the day when it comes to preventing 1,500 mm long hydraulic cylinders with an open pore from being scrapped. Despite the small opening diameter of 30 mm and the large processing depth, Pallas can coat the inner contour of the cylinder without leaving any pores.

Working in depth

The Neuss-based company Ruhfus System-hydraulik also benefits from this. Specializing in the customer-specific design and manufacture of complex hydraulic cylinders, the company needs a partner who can repair defects caused by material or machining errors and wear parts with high precision in a short space of time. Tolerances in the hundredths of a millimeter range are often required. Examples include tubes up to 15 m long for hydraulic cylinders with diameters of 400 to 500 mm and unit weights of up to 4 tons. To machine imperfections or internal grooves, only a small amount of heat may be applied to these components made of unalloyed structural steel so that the material structure does not change. At the same time, high precision is required.

Thanks to the integrated media supply, the iClad can process internal contours and blind holes with openings as small as 30 mm up to a depth of 500 mm. With an opening diameter of 50 mm or more, a screw-on taper can even be used to repair components up to 750 mm deep. This internal contour processing is made possible by the compact housing of the iClad, which contains all the components for beam guidance and shaping. The connection for the optical fiber and the supply lines for process media are located at the rear end of the optics. Active water cooling protects the optical components from overheating. An internal optical protection system prevents contamination or damage caused by particle deposits. In addition, the beam path is permanently purged with inert gas. For processing, the tube rotates around the fixed optics. Depending on the position of the work surface, the appropriate laser beam angle is selected so that even blind holes can be repaired.

Pallas selects the optimum technology for fast, efficient and cost-effective repairs based on the specific application requirements and general conditions, such as accessibility of the damaged areas or temperature sensitivity of the components. The wide range of systems, materials and processes available ensures that the customized solution is implemented within a short time. In an emergency, the company makes capacities available quickly, so that turnaround times of two days are not uncommon. If necessary, repairs can also be carried out on site at the customer's premises. In combination with the extensive range of services for pre- and post-treatment, customers from the plant and mechanical engineering, chemical, plastics and paper industries can therefore be sure of tailor-made solutions. am