In the demanding power gen industry, wear and tear on critical components is inevitable. This case study highlights the precision and power of our AL-Flak laser welder in restoring impeller bores to specification, even with intricate details like keyways.
The impeller presented a common issue: an undersized bore requiring a precise weld buildup of 0.020″ on the inner diameter.
Key challenges:
- Precise Material Addition: Achieve the required 0.020″ weld buildup to restore the bore to its correct inner diameter.
- Keyway Preservation: Carefully navigate the keyways to avoid any weld contamination and expertly cap the corners to ensure structural integrity and prevent future wear initiation points.
- Welding with dissimilar metals: Inconel filler on a 4340 material base.
Machine used: The Alpha Laser AL-FLAK 1200 watt fiber laser welder. This system’s exceptional control and precision make it ideal for applications demanding accuracy and minimal heat input.
The Process: Precision in Every Pulse
- Preparation is Key: The impeller bore was cleaned to ensure a defect-free welding surface.
- Strategic Layering: Utilizing the AL-FLAK 1200’s precise control, we applied thin layers of weld to achieve the required 0.020″ buildup. This layered approach minimizes heat input and distortion.
- Corner Capping Expertise: Special attention was paid to capping the corners of the keyways. This crucial step prevents stress concentrations and potential cracking that could arise from sharp edges. The AL-FLAK 1200’s power modulation capabilities allowed for controlled material deposition.
- Final Machining: Following the weld buildup, the bore was machined back to its exact specified dimensions, resulting in a perfectly restored component.
The Results: A Revitalized Impeller
The Alpha Laser AL-FLAK 1200 successfully restored the impeller bore to its precise specifications while completely preserving the integrity of the keyways. The 0.020″ weld buildup was achieved with exceptional accuracy, and the keyway corners were expertly capped, ensuring long-term reliability.
Why Choose Alpha Laser for Your Repair Needs?
This impeller bore repair is just one example of how Alpha Laser’s advanced fiber laser welding technology can provide cost-effective and high-quality solutions for component restoration. Our systems offer:
- Unparalleled Precision: Achieve micron-level accuracy for even the most intricate repairs.
- Minimal Heat Input: Reduce distortion and maintain the integrity of the base material.
- Versatile Material Compatibility: Weld a wide range of metals and alloys.
- Cost-Effective Alternative: Extend the lifespan of valuable components, avoiding costly replacements.