Titanova is a full service, ISO 9001:2015 certified laser job shop with a 35,000 lb. and 45 ft length parts handling capacity with Knoop and Vickers micro-hardness capability and Rockwell and Leeb rebound type macro-hardness measuring capability. We also have X-ray fluorescence alloy analyzers to chemically analyze laser cladding dilution. Titanova offers innovative solutions with rapid turnaround times at the highest value to our customers. We supply non-cutting laser processes such as:
Laser cladding is a process of overlay-welding a base metal with a corrosion, erosion or wear resistant (laser hardfacing) metal using diode lasers. The cladding process uses the lowest amount of heat resulting in the least possible distortion. Why produce an entire piece out of expensive alloys containing cobalt, nickel or chrome- when only the surface needs a coating. Learn more about laser cladding here.
Laser Cladding for Remanufacturing
Due to its low heat and distortion, laser cladding can also be used to add thin, weld metal layers back onto used parts, enabling the remanufacturing of the part. Most machines that wear out lose only a fraction of their mass due to wear. Titanova’s diode laser makes it possible to remanufacture many parts, including cast iron parts, that to date have been scrapped saving our customers’ time, energy and money. Learn more about laser cladding for remanufacturing here.
Laser Heat Treating
Laser heat treating makes steel harder and last longer, also known as case hardening. The laser diode heat treats precisely, significantly minimizing or eliminating distortion and the costly post-heat treating machining, bending or grinding associated with that distortion. Learn more about laser heat treating here.
Laser hardfacing is a unique laser cladding process that can apply a thin layer of welded metal with embedded super-hard particles producing extreme wear resistant coatings. This inherently low heat process produces low distortion, smoother, thinner and more uniform anti-wear coatings as compared to any other process. The lower heat does not burn out the carbides, achieving hard particle densities up to 75%. Learn more about laser hardfacing here.
Titanova’s laser diode’s unique beam shape allows high speed welding of distortion-sensitive parts such a thin gauge metals and stainless steel. Laser welding results in lowered distortion and reduced material costs without changing upstream processes which drops down to our customers’ bottom line. Titanova also has both hot and cold wire feed capability. Learn more about laser welding here.
Laser Additive Manufacturing
Laser additive manufacturing is a process using computer controlled laser cladding to create 3D metal profiles. Titanova uses the existing 3D profile of a part to program an automation laser cladding system to weld additional or replacement metal directly on the part. By adding metal back onto the part we can modify its shape and function or remanufacture it back to its original 3D shape. As technology becomes increasingly automated by the development of sensors and imaging systems, data will be used to increasingly control the laser additive process.Learn more about laser additive manufacturing here.
Laser Overlay Clad Tubing
Laser overlay clads are smooth and thin (0.030”), have very low dilution, are chemically pure and functionally the same as the thicker clads produced by arc-based overlay deposition technologies. The resulting fine grain structure enhances high temperature creep, erosion and corrosion resistance. Thin clads reduce weld-induced distortions, the risk of age related cracking, increase heat transfer and decrease slag adhesion.Learn more about for laser overlay clad tubing here.
Titanova’s main objective is to provide the highest value at the lowest risk to its customers. Our high value process development and contract manufacturing services are the lowest risk approach for our customers to be first to market with laser processed parts. Titanova understands that integration of these laser production processes for our customers is potentially the final step of our complete value package and we have the engineering expertise to implement the developed laser processes into a stand-alone integrated production system. Titanova has the expertise to integrate lasers for both large and small production systems meeting a variety of factory specifications. Learn more about integration here.
Laser glazing produces a robust super hard crack free surface with high lubricity by melting a thin surface layer of cast iron followed by rapid solidification. This “metallic glass” phase of iron-carbon is known as ledeburite which is a cementite-martensite and retained austenite composition that is typically greater than > 60 HRC. Learn more about laser glazing here.
Titanova laser systems’ uniquely shaped beam can silicon bronze-braze zinc coated steels and weld brass without the zinc fuming and spattering resulting in faster, cleaner and lower maintenance brazing process, increasing quality and saving our customers money. Learn more about laser brazing here.
Advantages of Lasers for Materials Processing
Lasers offer significant benefits for a variety of material thermal processing applications. Using laser energy for processing different materials is highly preferred for many situations because it is rapid, non-contact, and highly controllable radiant heating method as compared to traditional heating methods. Some of the most common applications for lasers in material processing include:
Laser welds offer minimal thermal deformation, is suitable for projects of all sizes, and is especially beneficial for welding thin gauge materials. The process is also significantly faster than standard arc based welding such as MIG, TIG or PTA welding.
At Titanova, we also offer both hot and cold laser wire feed welding. Our laser welding processes feature fast turnarounds, high throughput, low weld distortion, and exceptional weld quality. Laser welding is well-suited for welding items such as:
- Automotive components
- Stainless steel heat exchangers
- Thin gauge tubing
- Compressor and hydraulic parts
Laser Heat Treatment
Laser heat treatment is used for case hardening, but also can be used to temper. Some of the benefits of laser heat treatment include:
- Self-quenching, which is environmentally friendly and reduces acquisition and disposal costs for oils and other quenching fluids
- No post-processing requirements
- Minimal part distortion
- Localized heat treating
- No limitations on workpiece geometry
- Faster than most common heat treating methods
There are several types of laser cladding. The primary methods are laser hot wire cladding and powder cladding. In both methods, the laser beam and the clad material come together to create a molten pool on the surface of the workpiece. At Titanova, our laser cladding services offer superior quality over any other weld overlay process. Some of the benefits of laser cladding include:
- Less heat distortion
- Much thinner defect free clads
- Very low dilution
- Lower pre and post machining cost
- Lower overall material costs
Over the years, Titanova has completed a variety of projects spanning many different industries. Some of the industries we have worked with include:
- Mining. We have developed cost-saving laser heat treatment processes for large diameter seal carriers for off-road mining trucks. We have also conducted hard facing on mining bits.
- Military. For military and defense applications, Titanova completed laser heat treatment surface hardening turret ring of a .50-caliber machine gun mount on an M1 Abrams tank.
- Tooling. While laser heat treatment is ideal for hardening a variety of machine tooling, it’s worth noting that our proprietary tooling capabilities and methodology assisted in the design and development of the laser heat treating system we use today.
- Hand tools. Laser heat treatments enable focused hardening on various hand tools, such as the teeth on saws or pliers, without impacting the properties of the core material.
- Energy. Our laser cladding techniques enable us to repair the main shafts of wind turbines. We can repair the most commonly damaged main shaft journal area by cladding 1 mm of stainless steel on the surface, and we have a handling capacity up to 35,000 lbs.
- Transportation. Laser cladding is ideal for railroad special trackwork, such as frogs and crossing diamonds manufactured out of cast austenitic high manganese steel (Hadfield steel). This steel is used due to its excellent work hardening characteristics and high toughness, but creates a unique challenge to repair in the field using traditional metal inert gas (MIG) welding due to overheating. Titanova’s expertise in hot wire laser cladding enables on-track repair and offers several advantages over traditional welding, including lower heat input to the base material, faster deposition rates, and precision control of the process. This results in a more reliable, long-lasting repair.
- Automotive. Titanova has completed high-speed, low-heat hermetic welds for nested automotive cover pans quickly and without sacrificing weld quality. We were also able to successfully laser weld studs onto pans stamped from quiet steel.
- Locomotives. Laser cladding can be used to repair wear damage incurred on locomotive crank shafts. Since most new crank shafts are nitrided to enhance strength and wear, they are impossible to weld using the more common welding and cladding processes. Titanova has developed a proprietary laser cladding technique to address this problem.
Laser Material Processing From Titanova
Titanova offers an array of laser materials processing solutions in a variety of industries. Please contact us for more information about our services and capabilities, or go through our reading materials to better understand our service range and our full laser service solutions offering.