Targeted laser hardening of the tooth geometry of a drive gear to 56 HRC.
- Material: 42CrMo4
- Diameter of 510 mm
- 83 Teeth
Wear protection – precise and efficient
Laser hardening
High wear protection for longer service life
Laser hardening
Laser hardening is a very efficient process for the surface hardening of metal components. In this hardening process, a laser beam heats the component surface precisely and locally to high temperatures, followed by rapid self-quenching through the component volume.
The result: an extremely hard, wear-resistant surface with a tough material core with minimal hardening distortion and therefore significantly lower costs for post-processing.
High surface hardness
Produces high surface hardness with a tough material core
Minimal distortion
Minimal distortion of the component due to low heat input
No quenching media
No quenching media are required
No hard milling required
No hard milling is required
Homogeneous hardness
Homogeneous surface hardness in a clearly defined range
Sustainable
100 x more energy-efficient than through-hardening and resource-saving
High precision
Hardening of hard-to-reach contours on complex, intricate components
High productivity
Faster throughput times, even single pieces or small batches possible
Laser hardening – refinement for many applications
Our industry solutions
Laser hardening is used in the finishing of highly stressed, complex components and is used in industry, automotive, railroads, mechanical engineering, toolmaking, mold making, the oil and gas industry, mining, shipbuilding and agricultural engineering.
Automotive and mold making
- Forming dies
- Gripper jaws
- Injection molds
- Bending tools
Machine and gear construction
- Bevel gears
- Rollers and shafts
- Gear racks
- Machine beds
Agriculture and engineering
- Plow blade
- Conveying screws
- Cutters & Cutting tools
- Gear wheels and cams
Precise and efficient –
How does laser hardening work?
Laser hardening is a surface layer hardening process that achieves maximum hardness values on the surface layer of carbon-containing components made of steel or cast iron with minimum energy input. The aim is to improve wear behavior.
The laser beam briefly and precisely heats the top layer of the material to the austenitization temperature of the material used. This heating causes a restructuring of the carbon atoms in the metal lattice and creates an austenitization front in the material. No additional quenching medium is required due to the self-quenching, which takes place via the volume of the component. The rapid cooling leads to the formation of martensite, which results in a significant increase in hardness.
Thanks to its precision and efficiency, laser hardening is a particularly environmentally friendly and resource-saving technology. It is particularly suitable for small series and individual pieces, as it is extremely economical in these areas.
Laser hardening
References
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Drive gear
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Forming die
Laser hardening of a forming tools with dynamic laser beam guidance independent of the component geometry.
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Gear racks
Laser hardening with variable laser track width enables precise adaptation to different tooth geometries.
The post-processing costs could be reduced by 30 % compared to induction hardening.
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Forming tool
Laser hardening on all surfaces of a forming tool that are subject to heavy wear. The variable laser track width makes it possible to react to a wide variety of component geometries of the tool.
- Hardening depth: 1,2 mm
- Material: 40CRMnMo7
- Surface hardness: 60+ HRC
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Pressure sleeves
Mobile laser hardening of 14 m long and 25 t heavy pressure sleeves.
- Material: 42CrMo4
- Surface hardness: ca. 600 HV5 (55 HRC)
- Hardening depth: bis zu 1,5 mm
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Bevel gear
Laser hardening of a bevel gear with variable spot size during the hardening process.
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Forming die
Laser hardening of a 3D free-forming surface with dynamic laser beam guidance for demanding component geometries in a forming die.
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Cylinder
- Weight: 1.8 tons, length: 3.57 meters, diameter: 0.5 meters
- Material: 50CrMo4
- Surface hardness: 58+1 HRC
- Hardening depth: 1,5 mm
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Bending tool
Laser hardening of a bending tool for a significantly longer service life.
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Hardening a roller with mirror
With the mirror system, we can reach difficult areas such as deep-drawn edges or internal surfaces of cylinders or pipes during laser hardening.
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Pressing tool
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Laser hardening of larger tool surfaces of a pressing tool for the production of car body components for the automotive industry.
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Hardening with dynamic optics
Laser hardening independent of the geometry: radii, V-grooves, multiple steps or edges by means of dynamic, scan-like oscillating movement of an oscillating mirror.
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Forming tool
Laser hardening along the closing edge of a forming tool.
- Material: 40CRMnMo7
- Surface hardness: 60+ HRC
- Hardening depth: 1,2 mm
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Machine component
Laser hardening of a cylindrical machine component with different spot sizes.
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Forming die
- Material: 40CRMnMo7
- Surface hardness: 60+ HRC
- Hardening depth: 1,2 mm
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Screw shaft
- Material: 42CrMo4
- Surface hardness: 60 HRC
- Hardening depth: 0,5 mm
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Forging roll
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Laser hardening of a forging roll for longer service life and therefore greater cost-effectiveness.
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Turning part
- Base material: C45
- Surface hardness: 60 HRC
Comparison of hardening processes
Why laser hardening?
Laser hardening offers numerous advantages, particularly with regard to low distortion and reduced post-processing costs. Conventional hardening processes can result in considerable distortion, which requires complex and expensive post-processing steps such as grinding to size. Laser hardening, on the other hand, enables precise and targeted heat treatment that reduces distortion to a minimum.
Alternative hardening processes compared to laser hardening:
- Nitriding: low hardening depth, high energy input
- Flame hardening: low automation capability, no defined hardening range possible, high energy consumption and cooling required
- Induction hardening: no defined hardness range possible, high energy consumption and cooling required
- Oven hardening: highest energy consumption, affects the entire component, long process time
A convincing example of the advantages of laser hardening are gear racks that we process for a customer: By switching from induction hardening to laser hardening, post-processing costs were reduced by an impressive 30 %. This economic advantage makes laser hardening an attractive choice for companies looking to increase efficiency and reduce costs.
Technology for all component shapes
Processing optics for laser hardening
Depending on the geometry of the component, different processing optics ensure the optimum surface hardness.
ALOhard
Laser hardening with fixed laser track width
ALOhardzoom
Laser hardening with variable laser track width
ALOhardscan
Laser hardening with dynamic laser beam guidance
ALOhardmirror
Laser hardening with deflection mirror
Focus on technology and components
Laser hardening in video
Experience the precision and efficiency of laser hardening in action! In our videos, we show you how state-of-the-art technology and years of expertise come together to make your components even more durable and efficient.
Mobile laser hardening of 25-ton pressure sleeves
Laser hardening directly at the customer’s site! 14-metre-long and 25-ton pressure sleeves of an open-die forging press successfully hardened using mobile laser technology!
Laser hardening of a drive wheel with Ø 510 mm
Laser hardening of a drive wheel with a diameter of 510 mm, 83 teeth and made of 42CrMo4 material. Here, the tooth geometry is specifically hardened to 56 HRC.
Laser hardening of a forming tool
Laser hardening along the closing edge of a mold is used to harden high-strength plastic mold steels in a targeted manner and reduce wear.
Laser hardening of a roller with a mirror system
With the mirror system, we can reach hard-to-reach areas of the component during laser hardening, such as deep-drawn edges or internal surfaces.
Laser hardening of gear racks with zoom optics
The precise laser hardening of the tooth flanks ensures high gear quality and a long service life. The targeted and localized application of heat results in very little distortion of the component.
Laser hardening of a 1.8 t cylinder component
Laser hardening with precision, even for large components – such as this cylinder component with a length of approx. 3.6 meters, a diameter of approx. 0.5 meters and a weight of 1.8 tons.
Process and quality assurance
Metallography
With our in-house metallography, we support the development of your process and thus ensure the best possible quality and the most efficient process. Take advantage of sample production in the run-up to production to ensure optimum results on the components to be machined.
We offer the following testing methods in our metallography department:
- Production of macrosections
- Crack testing (penetration testing)
- Hardness measurement (Vickers HV0.1 – HV1; UCI HV5)
- Hardness depth profile measurement
Hardness depth profile measurement on material 51CrV4:
Are you interested?
Let’s talk.
Are you interested in the laser hardening process and need advice?
Please use the following form – we will get back to you as soon as possible.
Your cost advantage:
We harden at your site.
We offer laser hardening as well as laser powder cladding directly on site at the component.
This eliminates transportation and set-up times for the component as well as the associated costs and risks.
Answers to your questions
FAQ – Laser hardening
Here you will find answers to the most frequently asked questions about laser hardening. Our aim is to help you quickly and easily. If you cannot find the right answer here, please do not hesitate to contact us directly.
01.
Which components can be hardened?
02.
What dimensions can be processed with laser hardening?
03.
Does the surface need to be prepared?
04.
What hardness values can be achieved?
05.
What hardening depth is achieved with laser hardening?
06.
Does the surface need to be processed after laser hardening?
07.
What quantities can be processed with laser hardening?
08.
Are special devices required for laser hardening?
09.
What are the delivery times?
10.
What services do we offer in addition to laser hardening?