In various industries which use compressed gasses and fluids, compressor rotors play a very important role. They are used for providing the desired pressure and motion to the fluids, which are used in a variety of applications like pneumatic, air conditioning and refrigeration, generation of power, Oil and Gas industry, Chemical Industry, Aerospace Industry, etc.
Challenges:
During operation, some critical parts of the rotor, like the leading edge of the rotor vane and the vanes are exposed to different fluids and gasses. This part is impacted by different forces and velocities of fluids and also, to different chemical impacts from the fluids. This causes abrasion and wear, and due to repetitive stress and strain cycles, it can cause fatigue which shortens the working life of the compressor rotor.
Once the edge of the rotor blade is worn out, the compressor rotor can no longer give the desired performance. But, replacing the whole component is not feasible because the compressor rotor is very expensive, is complex and difficult to manufacture, and also, the downtime during the replacement hampers productivity.
Solution: Laser Cladding
A high energy Laser beam is used to melt the cladding material and this is deposited over the damaged sections of the rotor. This is kind of a metal deposition additive manufacturing process where the cladding material forms metallurgical bond with base material and restores the worn out section to its original dimensions.
Advantages of Laser Cladding :
Economic advantage :
Laser Cladding is a precisely controlled process, so it enables us to selectively address the worn out region and precisely restore the part to desired dimensions. It is highly efficient and minimizes the material requirements, and the worn out part is restored to its original state, lengthening its durability and eliminates the need to replace the part completely. Overall, it is much more cost effective compared to replacing the complete rotor assembly.
Enhancing Production efficiency :
It is a very fast process. It repairs the component in a short period of time, and it is returned to production within a short period of time reducing the production downtime. It increases the overall productivity and efficiency of the production.
Versatility and Customisation :
Laser Cladding can be done with a variety of materials with different compositions depending upon the application. It gives solutions tailored according to application of specific coatings or materials depending on the operating conditions, desired performance, and other requirements.
While considering Laser Cladding for compressor rotors, it is necessary to consult with professionals who have experience and expertise in Laser technology and Laser applications. We, at Laser Automation have experienced professionals who have vast knowledge in the field of Laser and we can provide customized solutions tailored to specific applications.
Based on clients requirements, we provide a Special Purpose Laser Cladding machine, integrating the Laser system with required automation for the process. Following video demonstrates Repair Cladding of a compressor rotor using Robotic Laser Cladding Machine. However, according to requirements, CNC based Laser Cladding machines can also be provided.
