Laser Hardening

Laser Hardening for Industrial Applications

Laser beam hardening of a steam turbine blade.
© Fraunhofer IWS
Laser hardening of a steam turbine blade.
Hardening of a gripper cam with high power diode laser.
© Fraunhofer IWS
Hardening of a gripper cam with high power diode laser.

Laser hardening is an innovative process for surface hardening of metals in which a laser beam heats the workpiece surface in a targeted manner. The rapid and controlled heating and subsequent self-cooling creates a martensitic microstructure that makes the surface of the material significantly harder and more wear-resistant. This process enables precise control of the hardness and depth of the hardened layer without subjecting the entire workpiece to thermal stress.

Typical applications can be found in mechanical engineering, the automotive industry and in tools where high wear resistance and durability are required. Laser hardening is often used for the treatment of gears, shafts and cutting tools. The process is efficient, environmentally friendly and enables the machining of complex geometries. Local heat treatment means that even components with sensitive areas can be reliably hardened.

The development of a new type of hardening process for precipitation hardening materials can be regarded as a special scientific achievement. A major objectives was to increase the service life of turbine blades made of precipitation hardening steel 16-4 PH. Such hardened turbine blades are now used in more than 50 turbines in large power plants.

Application Examples

The processes and system components developed at Fraunhofer IWS have been successfully transferred to industrial use in a large number of laser hardening systems. Examples are:

  • Laser hardening of cam pieces for highly efficient gasoline engines with cylinder deactivation
  • Laser hardening of inside surfaces in injection modules for modern automotive diesel car engines (about 9 million parts annually)
  • Temper zone-free laser hardening of sleeve bearing surfaces of automotive turbochargers (universal hardening system, approx. 90 different part types)
  • Robot-assisted laser hardening in tool and die making (systems in Germany, Switzerland, Italy, Slovenia)
  • Laser hardening of very large forming tools for the automotive industry (hardening portal, integration in 5-axis milling portal)
  • Universal hardening systems (based on a standard milling machine) for job shops, high volume production and development
  • Laser hardening of hydraulic components (partly with integration into automatic bar turning machines)
  • System for laser hardening of brake components for commercial vehicles
  • Systems for laser hardening of steam turbine blades (Siemens, Fuji Electric)

Laser Beam Hardening in Tool Making

Integration of Laser Beam Hardening in Machine Tools

Laserintegration in Manufacturing Technology – LiFt Initiative

Equipment

Multi Station Processing System for High Power Diode Laser

Laser System for the Simultaneous Processing with High Power Diode Lasers

Heat Treatment Furnace