CNC Robotics installs cutting edge Laser cladding robotic cell for Laser Metal Deposition (LMD) coating and repair at ASCO Engineering and Surface Technology

Background

The installation of cutting-edge technology supplied by CNC Robotics at ASCO Engineering and Surface Technology means that the company can now offer a wider range of machining, coating and repair processes. The addition of a robot-based system for laser-metal deposition and hard facing cladding also known as laser cladding means that CNC Robotics has extended the range of manufacturing techniques used at ASCO. Andy Deegan, Chairman at ASCO believes that the system has made their company more versatile than any equivalent supplier in Europe. Therefore, creating the ultimate one-stop-shop.

Based in Skelmersdale, Lancashire, and with a second site in Dubai, ASCO offers a comprehensive service incorporating CNC precision machining, fabrication, surface coating, diamond grinding and superfinishing repair technologies. As well as having an extensive machine shop equipped with CNC lathes and machining centres. The site includes specialist coating equipment, including unique systems specifically designed for the company’s processes. All manufacturing at the company is supported by an in-house metallurgical laboratory for testing coatings to international standards. Furthermore, CNC coordinates measuring machines for dimensional inspection ensuring precision components can be certified to be within microns.

Requirements

Laser-metal deposition and hard facing cladding, also known as laser cladding allows coatings, such as Tungsten Carbide, Stellite and Inconel to be deposited with significantly lower and more localised heat affected zone (HAZ), even with materials that are difficult to weld. This means that the process has minimal impact on the mechanical properties of the substrate material and reduced potential for distortion and damage to the chemistry & structure of the base core material.  In addition, the small melt pool that is formed enables the processing of very complex geometries in a single set-up, when depositing protective surfaces, undertaking repairs or creating near-net shapes.

The ability to work with very complex shapes is supported by the flexibility of the robot cell. The robot offers six-axis movement, while specially designed work holding adds a further three axes, giving the potential for nine-axis operation. In addition, a novel head can be fitted to allow the internal cladding of bores up to 2 metres in length and down to 55 mm bore size.

Andy Deegan, Chairman of ASCO Engineering, had used robots in the company’s Thermal spray booths for several years and recognised the advantages in repeatability and consistent quality that they offered. With the high levels of dust and noise in the booths, they also offered health and safety benefits. However, he felt extra support would be needed to develop the new process.

Solution

By chance, Andy met Jason Barker, Chief Technical Officer at CNC Robotics, at a classic car show. “We started talking about Jason’s car and things developed from there,” remembered Andy. “I explained my idea for a robot-based laser deposition system to Jason and it soon became clear that he was the right man to make it all work.”

The main challenge for the system resulted from the variety and complexity of the shapes being processed at ASCO Engineering, since the laser has to be as near as possible to 90° to the surface of the part. This was overcome with a KUKA robot that includes very few restrictions on its range of movements.

Head of the Laser Department at ASCO, Andrew Mawsley worked with Jason and the CNC Robotics team to install and test the new process. “It seemed quite complicated at first but, once Jason had helped me to get used to the system, it became much easier, even for the more complex jobs,” he said. Andrew had a basic knowledge of C++ programming from his university course. He also uses Orange Editor software on a laptop to create programs for the robot. “Using the laptop, rather than the robot control, means that I can start one process running and begin programming the next job,” he explained.

While the new system has been used predominately for adding coatings to new parts, it has also proved valuable in component repair. For these projects, repair material is typically laid down in layers of up to 1 mm per pass and then ground back to give the final surface. Dependant on clients requirements ASCO are, in reality, able to clad to any thickness.

Benefits

The main benefit of the new system is the consistency of the results. Many of the coating materials used at ASCO Engineering are very expensive blends that are needed to give the necessary corrosion resistance and wear resistance. Many of the parts made by the company are used in demanding applications. For example, the oil and gas and power generation, mining and aircraft industries where any failures can lead to costly losses in production.

“The robot system is at its best when we are working with batches of parts,” claimed Andy Deegan. “We can process the first part, confirm that it is dimensionally accurate and carry out full laboratory checks on the surface integrity. Once we know we have set the correct parameters for the first part, we can rely on the repeatability of the robot to ensure that the rest of the batch will be equally good.”

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