Revolutionizing Asset Integrity: LaserClad for Corrosion and Wear Protection in the Mining Industry

CANADA, Quebec - Nov. 19, 2025 - PRLog -- Overview of LaserClad Technology
Laser cladding is an advanced surface engineering technique that uses a high-energy laser to melt and fuse metallic powder onto a substrate, forming a dense, metallurgically bonded coating with minimal heat input. This preserves base material properties and provides stronger adhesion and lower dilution—typically under 5%—than thermal spraying or weld overlay. Low dilution maintains chemical integrity and ensures effective corrosion protection.

Material Selection for Corrosion Resistance
Selecting the correct cladding alloy is critical and must be tailored to the corrosive and abrasive conditions of each application. For superior corrosion resistance, Ni-, Cr-, and Co-based alloys are typically preferred.

• WC-Ni-Based Alloys (e.g., Castolin Eutectic LaserClad 41460-SWC):
  Tungsten carbide nickel-based metal matrix alloys are effective in a wide range of corrosive media due to chemical stability and extremely high abrasion resistance.
• Cr-Based Alloys (e.g., Castolin Eutectic LaserClad 41625):
  High chromium content forms a stable Cr₂O₃ passive layer, providing a strong barrier against pitting and crevice corrosion in chloride-rich environments.
• Co-Based Alloys (e.g., Castolin Eutectic LaserClad 41006):
  These alloys balance corrosion and wear resistance, ideal for components exposed to chemical attack and mechanical abrasion, such as slurry transport systems.

Application Design and Thickness
A successful laser cladding application depends heavily on coating design. A uniform thickness of 0.75–2 mm is recommended to create an impervious corrosion barrier and fully isolate the substrate. Consistent thickness on complex geometries requires precise control of laser parameters to prevent thermal stress and micro-cracking that could compromise integrity.

Quality Control and Verification
To ensure required performance, rigorous quality control and verification are essential.

• In-Process Monitoring: Real-time melt-pool monitoring maintains stable parameters and reduces defect risk.
• Microstructural Analysis: SEM and microscopic inspection verify a fine-grained, homogeneous structure free from porosity or cracks.
• Corrosion Testing: Techniques such as Potentiodynamic Polarization quantify corrosion rates (e.g., Icorr µA/cm²) to confirm the coating meets corrosion resistance specifications.

Summary and Conclusion
LaserClad provides durable, low-dilution, metallurgically bonded coatings that significantly enhance corrosion and wear protection in demanding mining applications. With optimized alloy selection, precise control of coating thickness and microstructure, and strict verification protocols, LaserClad offers a reliable, long-lasting solution that reduces maintenance downtime and extends component life while improving overall operational efficiency.

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