In the manufacturing industry, time and cost are everything – which is why there is always a tug-of-war between manufacturing technologies. One such technology involves the joining of metals. Fusing metals can be done via welding or with this fairly new technology called laser cladding.
Laser cladding technology and welding machines are both popular choices; however, what sets them apart? Keep reading to learn which is the better choice!
What is Laser Cladding?
Laser cladding is a reliable process that uses lasers to bond metal alloys onto an existing surface. The extreme heat produced by the laser melts and binds these materials, resulting in a hard-wearing connection. Furthermore, this laser cladding technology provides corrosion resistance for extended durability!
What is a Welding Machine?
A welding machine, or welder, is a powerful tool used to join two pieces of metal together with heat and pressure. Although it produces joints that are strong enough for many applications, such as piping and structural components, they do not provide corrosion-resistance like laser cladding does. The general recommendation for welding machines is to use them more for repairs than new construction.
The Past Vs. The Future: Wielding Machine Vs. Laser Cladding
When it comes to production and fabrication, welding machines are a long-established solution for industrial professionals, whereas laser cladding is newer technology. Let’s compare them further:
Welding Machines
Welding machines have been the cornerstone of industrial manufacturing and production processes for generations. This process involves joining two pieces with heat and pressure, often accompanied by an inert gas for added security. In doing so, welders can create unique structures that are far stronger than what would be achievable without this technology.
Although welding machines offer numerous advantages, they do have some drawbacks. These machines can only be used with a specific set of metals and may not work on other materials or special alloys. Apart from that, the high temperatures involved in welding causes distortion and warping, which becomes problematic when attempting to create highly precise parts.
Laser Cladding
By comparison, laser cladding technology is relatively new and utilizes lasers to rapidly join two pieces of materials. If we compare it to welding, this method offers greater accuracy across a multitude of different alloys as well as reduced material distortion due to its lower operating temperature.
With its pinpoint accuracy and affordability, a laser cladding machine is an ideal tool for making high-precision parts with tight tolerances. Moreover, it can be used to repair existing components that have been worn down as well as create new ones from scratch.
Comparing Features: Welding Machines Vs Laser Cladding
| Factors | Welding Machines | Laser Cladding |
| Usage of Method | Heat-based | Laser beam |
| Speed | Slower | Faster |
| Precision | Less precise | More precise |
| Design options | Limited | Wide range |
| Cost | Higher | Lower |
| Performance | Inferior | Superior |
| Safety | Hazardous | Safer |
For decades, welding machines have been the reliable option for joining metals. But now, with laser cladding machines stepping up to the plate, a seismic shift has taken place in weld technology! Let’s take a look at how things used to be and compare it with what we have now:
Methodology:
Welding machines rely on heat to efficiently fuse metal pieces together, with the operator guiding a welding gun over seams and molten metal, filling in any gaps. Laser cladding machines use lasers that melt and join powdery metals onto substrates.
Speed:
Welding machines tend to be slower than laser cladding, especially when the material is thick. Laser cladding offers much faster and more efficient results since it’s fully automated.
Precision:
Although welding machines are serviceable, they cannot match the precision of laser cladding. The operator must have a steady hand to avoid overheating and causing deformations in the metal. In comparison, laser cladding offers incomparable accuracy that can be modified with different levels of power for an ideal, high-quality finish.
Design options:
Welding machines have limitations when it comes to complex designs, and it’s not possible to weld thin pieces of metal without them deforming. Again, laser cladding takes the cake as it can create complex geometries and intricate designs that are not possible with welding machines.
Cost:
Welding machines are notoriously energy-hungry, leading to higher production costs. But this is not the case with laser cladding. It is an automated process that demands less manual input, which aids in keeping the cost of production minimal.
Performance and Durability:
The use of welding machines to produce parts can result in defects, porosity, and other issues that suppress product quality. However, laser cladding eliminates these problems leading to superior performance.
Safety:
Welding machines are known to produce hazardous gasses, fumes, and materials that can be life-threatening to workers’ health. Thankfully, laser cladding is a much safer option as it does not produce such harmful substances.
What Does The Future Hold For Laser Cladding?
The manufacturing field is in a constant state of evolution, and laser cladding has already made an impact as a cutting-edge technology. But, there are still more advancements that will take it to the next level.
Automation and Robotics:
As robotics technology progresses, the potential of automating laser cladding processes grows. With robots taking on more tasks currently done by human operators, production will become faster and cost-efficient. For this reason, it’s likely that automation in laser cladding is one of the most promising areas for development.
AI and IoT Integration:
Laser cladding can be combined with the most cutting-edge technologies, such as Artificial Intelligence and the Internet of Things, to further develop laser cladding. This will create intelligent systems that are capable of monitoring production needs in real-time, allowing for more efficient procedures and higher quality products.
Material Compatibility Expansion:
To conclude, laser cladding’s material compatibility can always be improved and expanded. Though it already has a wide range of applications with several distinct materials, manufacturers have the potential to create more inventive products that feature distinctive properties and characteristics if they continue to expand their scope.
Conclusion
Laser cladding has a brilliant future ahead, with groundbreaking advancements just around the corner that will catapult this technology to great heights. As manufacturing advances, laser cladding will continue to be an integral part of its evolution and development.
