Discover a better way to manufacture, repair and maintain metal components
Wire laser additive manufacturing is a game-changer for industries prioritising precision, cost-efficiency and occupational safety. PhotonWeld aster-Pro gives you the control and flexibility you need to stay competitive.“
Why industry is embracing WLAM
100% material utilisation: No waste compared to 10-20% loss in powder processes.
Faster processing: Higher deposition rates reduce production times.
Safe and clean: No harmful dust, simplifying handling and storage.
Ever-growing material versatility: Wide range of standardised wire materials readily available.
Minimal base material impact: Precise energy control prevents unwanted material changes.
Superior surface quality: High-quality finish significantly reduces post-processing.
What customers love about the PhotonWeld Master Pro Series!
Industry-leading precision: Our advanced control technology delivers unmatched accuracy, minimal material waste and consistently high-quality outcomes.
Effortless integration: Seamlessly integrate our PhotonWeld systems into your existing production lines with minimal setup and maximum compatibility.
Proven return on investment: PhotonWeld Pro Series consistently demonstrate measurable cost savings through reduced waste and enhanced operational efficiency.
Premium customer service: Our experts offer seamless support, from feasibility study to production.
Productive wear plate surface overlay welding machine
Layer Build-up with Powder or Wire
Laser powder cladding: Metal Deposition with Metal Powder
The laser beam connects the metal workpiece with the powder that is applied. Various steels, cast iron, copper, aluminum, nickel-based and cobalt-based alloys can be used as the base material. The layers are formed from iron-based alloys (low-alloy steels, tool steels, stainless steels), nickel-based alloys such as Inconel (625, 718, 738), cobalt-based alloys such as stellites, high-temperature alloys, aluminum alloys, titanium alloys and materials containing carbides, to offer additional wear protection. The decisive factor is the availability of the filler material in powder form, with a typical particle size of 40-120 µm, to enable the use of a coaxial powder nozzle. Laserline LDM and LDF diode lasers achieve excellent results when melting metal powder: excellent adhesion, high precision, virtually no porosity and limited cracking with a high degree of hardness and minimal deformation. In most cases, the surface that results from the mixing does not require any further machining. Conventional hard facing processes, such as plasma powder deposition welding, on the other hand, do not achieve a sufficiently long service life for many applications.
Laser Wire Cladding: Metal Deposition with Metal Wire
In this process, the laser beam melts the wire that is fed in and the material of the component to be coated. Wire with diameters of approx. 0.8 to 1.6 mm is used, which is led to the additive welding process by commercially available wire feeders. Today, it is estimated that 90% of the applications involve being coated with powder and 10% with wire. Areas of application for laser deposition welding with wire include the repair of components and the functionalization of surfaces. The process is particularly economical and clean, and reworking is reduced to a minimum.
Advantages of Laser Deposition Welding:
Advantages of Laser Welding Recharging:
- Low Mixing (less than 5%)
- Metallic Bond and Low Porosity
- Very Low Distortion Due to Low Energy Input
- Good Surface Quality with Low Roughness
- High Metal Efficiency (up to 99.8%)
- High Process Speed (up to 5 m/min)
Through the precise control of the laser beam and the welding material, laser deposition welding enables high reproducibility and quality of the welds. At Lasermach, our machines are capable of processing workpieces both externally and internally. This includes the use of optics developed through our laser system technology. Our optimized process achieves layer thicknesses of 0.5 to 30mm and track widths of 1 to 8 mm. By applying multiple layers, almost any type of surface geometry can be created or refined through laser coating. It is an extremely versatile technique used for maintenance, repair, surface enhancement, and the production of custom components, particularly in fields such as aerospace, automotive, tool and mold making, and the energy sector.
Minimise waste
Laser-cladding can extend the life of parts where other traditional methods would fail. This helps save resources and the planet.
It’s an environmentally friendly option that reduces the disposal of old parts and the creation of brand new ones every time something is worn. Working at the scale required by heavy industry, the potential amount of wasted machinery that can be saved is immense.
Tough jobs need tough surfaces
Laser cladding has fundamental differences when compared to other cladding technologies such as thermal spray, plasma coating, or arc welding. Using a Lasermach high power PhotonWeld Master Pro handheld laser welding system, a new surface layer is created with a different material to the substrate (the underlying surface).
A dense, pore-free, and extremely hard surface is firmly bonded, with little or no distortion to the part. This is critical to the types of industry that require this service, such as mining and power generation.
Cost-effective repairs
Heavy industries, such as automotive, aviation, mining and power generation, deal with a lot of compromised machinery. Your clients have 2 options—they can replace the machinery at great cost and waste. Or repair it.
At approximately a third of the price of new parts, you can return them back in original state with a repaired part using laser cladding. This is incredibly cost-effective for your clients, making your services an attractive proposition. And they also get a part that’s stronger and tougher than the original.
Salvage worn parts
The wear and tear of machinery is a common and costly issue faced in heavy industries like mining, oil, and defence. Using our handheld PhotonWeld Master Pro to repair the surface of compromised parts offers many benefits. The laser interacts with the metal wires to create a tough cladding that’s fused metallurgically to the surface you’re repairing. The result? Extended lifetime and increased durability of the part. Learn more about our custom solutions here
Laser Repair Welding with Cladding
Solid new coatings - high-quality welding results - low production costs
Is your component wearing out?
With our handheld laser welder you weld it like new. With handheld laser cladding, you can specifically improve the surface quality of your components and increase their durability.
Laser Cladding from Lasermach applies an ultra-hard protective layer. Precise, resource-efficient, and more cost-effective than a replacement part.
- Longer service life
- Hardly any heat exposure
- Time & cost savings
- Reduce downtime
- extend equipment life
- cut replacement costs.
Laser cladding
Is your component wearing out?
Our machines laser it as new. We laser it like new.
Laser Cladding with Photonweld A-Pro series or A-Pro master Series applies an ultra-hard protective layer.
Precise, resource-efficient, and more cost-effective than a replacement part.
Commercial challenge
Large bearings, rollers, and other wear components present a significant challenge to the mining and energy industry. They’re expensive to purchase and dispose of when worn. And it can be challenging to find replacements.
Laser cladding is an environmentally friendly, cost-effective way to resurface worn components used in the mining and energy sectors.
Industrial applications of wire additive manufacturing processes
Proven across industries, from mining and energy to tooling, steel and recycling
3D repair/repair welding
Remanufacturing
Wear protection
Preventive maintenance
Reverse engineering
Retrofitting
Part individualisation
Prototyping