Laser cladding is a technique that uses the laser to apply a thin layer of specialized material onto the product surface, to the strength, durability, and resistance to wear, corrosion, and several other physical defects. The technology has wide applications in different fields of industry such as automotive, aerospace, and also oil and gas companies. Laser cladding has been growing due to the post-welding processing, and equipment longevity. Also, the increase in demand for different products made by additive manufacturing, besides the necessity for cost-effective repairing procedures is boosting the demand for laser cladding. With the continuous improvement of laser systems’ precision, speed, and versatility, the laser cladding market is poised for robust growth in the coming years.
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The market of laser cladding is anticipated to grow at a CAGR of 9.5% by 2031. North America and Europe dominate the market primarily attributing to the developed industrial environment and technology. Nevertheless, the Asia-Pacific region is identified as having the highest growth rate owing to the rising industrialization and extensive investments in R&D. The current trends highlight that as technology advances, more companies will gain insights into laser cladding and embrace its application.
Over the last couple of years, laser cladding technology has attracted significant technological advancement and innovations. A notable advancement is the capability to combine the laser cladding technique with other Additive Manufacturing (AM) technologies. The combination of laser cladding and AM techniques such as, Laser Powder Bed Fusion (LPBF) or Directed Energy Deposition (DED), enables the construction of intricate components that combine several material types and properties.
Another innovation is the high-power fiber lasers. These lasers are more efficient compared to the traditional CO2 or solid-state lasers. They are characterized by a better quality of the beam and have been revealed to be more reliable. For instance, in the oil & gas industry laser cladding with high-power fiber lasers is used to coat the surface of drill bits and pipelines and parts prone to wear or corrosion, thus increasing its life.
Among current laser cladding advancements, one can mention hybrid laser cladding, which uses the laser solution in combination with other methods of surface engineering. For instance, laser cladding can be combined with arc welding, which is termed laser-arc hybrid cladding since arc welding possesses a high deposition rate, and on the other hand, laser cladding possesses high accuracy and low heat input. It also enables concept processing to occur at a much quicker pace, as well as addressing larger areas all at an economical rate.
Real-time monitoring of the process and control system is yet another revolution in laser cladding technology. These systems use advanced sensors to measure some of the critical factors such as, the size of the melt pool, the temperature of the melt pool, and the rate of deposition in real-time. This information is processed by feedback loops of control algorithms which allow for changing the laser power, the rate at which powder is supplied in the next layer, or even the position of the nozzle during fabrication.
Laser cladding can now also be applied to novel materials, leading to the formulation of high-quality alloys. Cobalt-based alloys which find application in high strength, wear, and corrosion-resistant niche applications in the high-temperature sectors are expected to experience above-average growth. These alloys are of immense significance in aerospace specifically for use in turbine blades and oil, and gas industries particularly in downhole tools.
From the strategic perspective, strong market dynamics in the laser cladding industry include market collaboration, product development, and geographical expansion. The is currently dominated by Coherent Inc., Trumpf GmbH + Co. KG, Oerlikon Group, IPG Photonics Corporation, and Laserline GmbH. The market players are making significant contribution towards market growth, by the adopting of various business strategies.
For instance, in December 2020, Coherent’s partnered with PT Laser Indonesia to introduce laser cladding services using a Coherent high-power diode laser system. Similarly, Laserline GmbH, specializing in high-power diode lasers, has been collaborating with system integrators to develop turnkey laser cladding solutions. Their focus on user-friendly, automated systems has made laser cladding more accessible to small and medium enterprises, particularly in sectors like tool and die-making.
Overcoming Integration Challenges
The laser cladding industry has several critical obstacles that limit its expansion. One of the major challenges is the high initial cost of using laser cladding systems which makes it hard for small and medium businesses to afford. This financial barrier is aggravated by the acute shortage of skilled workforce that is required for operating and sustaining such systems.
Other negative challenges that affect the laser cladding business are environmental issues. It sometimes requires the use of rare earth materials, which are necessary to achieve various performance-enhancing coating types. However, the extraction and processing of these elements entails the degradation of the ecosystem and the production of toxic waste, it is not a sustainable practice.
Another difficulty is the slow acceptance of laser cladding within the industrial applications of laser technologies. However, mainly due to its ability to perform detailed processes, laser cladding is considered a complex, specialized technology. This can cause uncertainty among potential users, most of whom would rather opt for relatively simple and less innovative surface treatment techniques. This perception is further reinforced by the fact that there are no standard methods in laser cladding processes. Due to a lack of widely held criteria for defining process parameters, quality assurance, testing, and clad quality can vary.
Supply chain aggression stands as yet another challenge. Some of the important parts, including, laser source, optical parts, and some alloy powders, have limited suppliers, and there is truly a high degree of concentration in a regions such as, China. It is vulnerable to geopolitical tensions, natural disasters, or other global crises which may result in shortage scarcity.
Finally, post-processing needs can also lead to increased costs and challenges when laser cladding is used. Subsequently, laser-cladding parts must undergo other surface treatments comprising machining to achieve the final dimensional accuracy, or heat treatment to relieve residual stresses. While these additional steps prolong the general product creation timeline and raise its cost, they also often involve the cooperation of several manufacturing departments or outsourcing, which introduces the organizational layer.
In conclusion, the laser cladding market is a promising and rapidly developing subject that offers vast scopes for the development and application of modern manufacturing methods. Despite the threats that seem to plague the growth of the laser cladding market including high costs, shortage of skilled personnel, environmental issues, and supply chain issues, they are all surmountable. To counter these multiple-faceted risks associated with laser cladding, the different players in the market should come up with an overall strategic approach.
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