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Wear protection – precise and efficient

Laser hardening

Precise wear protection for components

Laser hardening

Protect your components – before wear stops your production.
Unplanned downtime, expensive repairs, production delays: Component failure costs time and money. With our precise laser surface hardening, you can increase the stability of your components in a targeted manner – economically, efficiently and with virtually no distortion.

During laser hardening, the surface of your workpiece is precisely heated and then rapidly quenched by the component volume. The result: an extremely hard, wear-resistant surface layer with a tough core material – ideal for the highest loads and reduced post-processing costs.

Secure your components for the long term – get a non-binding consultation now!

Laser hardening - component hardened with dynamic laser beam guidance

Advantages of laser hardening

Laser hardening - High surface hardness

High surface hardness

Produces high surface hardness with a tough material core

Laser hardening - minimal distortion

Minimal distortion

Minimal distortion of the component due to low heat input

Laser hardening - no quenching media

No quenching media

No quenching media are required

Laser hardening - no hard milling

No hard milling required

No hard milling is required

Laser hardening - homogeneous hardness

Homogeneous hardness

Homogeneous surface hardness in a clearly defined range

Laser hardening - Sustainable

Sustainable

100 x more energy-efficient than through-hardening and resource-saving

Laser hardening - High precision

High precision

Hardening of hard-to-reach contours on complex, intricate components

Laser hardening - High productivity

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

Laser hardening for automotive and mold making
  • Forming dies
  • Gripper jaws
  • Injection molds
  • Bending tools

Machine and gear construction

Laser hardening for machine and gear construction
  • Bevel gears
  • Rollers and shafts
  • Gear racks
  • Machine beds

Agriculture and engineering

Laser hardening for agriculture and agricultural technology
  • Plow blade
  • Conveying screws
  • Cutters & Cutting tools
  • Gear wheels and cams

Surface hardening with laser

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 Function scheme

Laser hardening

Examples of use

  • Laserhärten eines Antriebsrades

    Drive gear

    Targeted laser hardening of the tooth geometry of a drive gear to 56 HRC.

    • Material: 42CrMo4
    • Diameter of 510 mm
    • 83 Teeth
  • Laserhärten eines Umformwerkzeuges

    Forming die

    Laser hardening of a forming tools with dynamic laser beam guidance independent of the component geometry.

  • Laserhärten einer Zahnstange

    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.

  • Laserhärten eines Formenwerkzeuges

    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
  • Mobiles Laserhärten von 25 t schweren Druckhülsen

    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

    Learn more

  • Laserhärten eines Kegelrades

    Bevel gear

    Laser hardening of a bevel gear with variable spot size during the hardening process.

  • Laserhärten eines Umformwerkzeuges

    Forming die

    Laser hardening of a 3D free-forming surface with dynamic laser beam guidance for demanding component geometries in a forming die.

  • Laserhärten eines Zylinders

    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
  • Laserhärten Bauteil Biegewerkzeug

    Bending tool

    Laser hardening of a bending tool for a significantly longer service life.

  • Laserhärten einer Walze mit Spiegelsystem

    Surface hardening a roller with mirror

    With the mirror system, we can reach difficult areas such as deep-drawn edges or internal surfaces of rollers or pipes during surface hardening.

  • Laserhärten größerer Werkzeugflächen eines Presswerkzeuges zur Herstellung von Karosseriebauteilen für die Automobilindustrie

    Pressing tool

    Laser hardening of larger tool surfaces of a pressing tool for the production of car body components for the automotive industry.

  • Härten mit Scanoptik

    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.

  • Laserhärten entlang der Schließkante eines Formwerkzeuges

    Forming tool

    Laser hardening along the closing edge of a forming tool.

    • Material: 40CRMnMo7
    • Surface hardness: 60+ HRC
    • Hardening depth: 1,2 mm
  • Laserhärten Bauteil Maschinenbauteil

    Machine component

    Laser hardening of a cylindrical machine component with different spot sizes.

  • Laserhärten eines Umformwerkzeuges

    Surface hardening of a forming die

    • Material: 40CRMnMo7
    • Surface hardness: 60+ HRC
    • Hardening depth: 1,2 mm
  • Laserhärten einer Schneckenwelle

    Screw shaft

    • Material: 42CrMo4
    • Surface hardness: 60 HRC
    • Hardening depth: 0,5 mm
  • Laserhärten einer Schmiedewalze

    Forging roll

    Laser hardening of a forging roll for longer service life and therefore greater cost-effectiveness.

  • Laserhärten Bauteil Drehteil

    Turned part

    • Surface hardening with laser
    • 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

This processing optic for laser hardening has a fixed laser track width. It is compact, lightweight and robust in use.

Area of application: Laser hardening with a constant track width on series parts for mechanical engineering as well as on tools and moulds.

Laser hardening with a fixed track width
Laser hardening with a fixed track width
Laser hardening with mirror system
Laser hardening with mirror system

  ALOhardzoom  

Laser hardening with variable laser track width

The ALOhardzoom processing optics enable the laser track width to be changed flexibly in the x and y directions during the hardening process.

Area of application: Laser hardening with variable track widths of geometries from a wide and changing range of components in tool and mold making and mechanical engineering.

Laser hardening of a roller with a variable track width
Laser hardening of a roller with a variable track width
Laser hardening with zoom optics

  ALOhardscan  

Laser hardening with dynamic laser beam guidance

This processing system is the ultimate tool for the most demanding hardening processes. A dynamic, scan-like oscillating movement is generated via an oscillating mirror, which creates the conditions for highly efficient heat field control.

Area of application: Laser hardening regardless of the component geometry, e.g. on radii, V-grooves, multiple steps, edges or any geometries of individual and series parts from tool and mold making and mechanical engineering.

Laser hardening of a drawing punch with dynamic track width
Laser hardening of a drawing punch with dynamic track width
Laser hardening on different geometries

  ALOhardmirror  

Laser hardening with deflection mirror

With the deflecting mirror system, we can reach difficult areas such as deep-drawn edges or internal surfaces of cylinders or pipes during laser hardening. The laser hits the component surface at a 90° angle for optimum hardening.

Area of application: Laser hardening regardless of the component geometry, e.g. on multiple steps, edges or internal surfaces of individual and series components from tool and mold making and mechanical engineering.

Laser hardening with a deflecting mirror
Laser hardening with a deflecting mirror
Laser hardening with a deflecting 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

Video vom Laserhärten einer Walze mit Spiegelsystem

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:

Hardness depth profile measurement

What others think about us

ALOtec from a customer perspective

“We have actively opted for laser hardening for selected projects because we are very satisfied with the performance and would like to pass on the benefits of laser hardening to our customers!”

Laura Erbert, Project management Getriebebau Nossen

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.

  Laser hardening on site  
Mobile laser hardening of pressure sleeves for an open-die forge

Answers to your questions

Answers to frequently asked questions (FAQ)

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?

Steels with a carbon content of 0.3 % or more and certain cast iron alloys are suitable for laser hardening. Typical materials include C45, C60 or 42CrMo4.

  02.

  What dimensions can be processed with laser hardening?

We harden both small precision parts and large components. For very large workpieces, we offer mobile laser hardening on site, for example on pressure sleeves. Mobile laser hardening of pressure sleeves

  03.

  Does the surface need to be prepared before laser hardening?

Yes, the surface must be clean, free of grease and metallically bright. Rust, coatings or heavy soiling must be removed before laser hardening.

  04.

  What hardness values can be achieved by laser hardening?

Depending on the alloy, very high hardness values are achieved, sometimes up to over 60 HRC.

  05.

  What hardening depth is possible with laser hardening?

Depending on the material and geometry, we achieve hardening depths of up to 1.5 mm.

  06.

  Does the surface need to be reworked after laser hardening?

A thin oxide layer (scale) forms after laser hardening. This can be removed by grinding, milling or blasting. We offer glass bead blasting for this purpose.

  07.

  Is surface hardening the same as laser hardening?

Surface hardening is the generic term for various processes that harden the surface of a workpiece. Laser hardening is a specific surface hardening process with many advantages over other surface hardening processes.

  08.

  What quantities can be processed?

We process all quantities – from individual parts to series with several thousand components – efficiently and economically.

  09.

  Are special devices required for laser hardening?

Not in most cases. Our robot-based laser hardening is very flexible. If special fixtures are required, we develop these internally in our design department.

  10.

  How long is the delivery time for laser hardening?

Our standard delivery time is approx. 2 weeks, depending on component size and quantity.

  11.

  What additional services do we offer in addition to laser hardening?

We offer glass bead blasting, metallography, hardness measurement and various deposition welding processes (powder, wire, arc welding) as well as a pick-up and delivery service.