weldmetrix has expanded its technological capabilities in real-time laser cladding monitoring through the acquisition of two key analysis technologies from HPL Technologies. This strategic move integrates specific solutions for melt pool analysis and powder-gas jet analysis (PGSA) directly into the weldmetrix portfolio. The acquisition aims to provide comprehensive process monitoring for demanding industrial applications, specifically including the production of coated brake discs.
Highlights
- Technology Acquisition: weldmetrix integrates in-situ camera and PGSA technologies from HPL Technologies.
- Brake Application: The solutions target high-precision components like brake discs, plain bearings, and rollers.
- Cost Efficiency: Holistic monitoring can yield savings of over €200,000 annually for high-volume brake disc production lines.
- System Integration: New tools are merged into the PROMOS Monitoring Suite for unified real-time analysis.
Advanced Process Analysis Technologies
The newly acquired technologies originate from the WECOGUARD development project, a collaboration between HPL Technologies and the Fraunhofer Institute for Laser Technology ILT. These systems address specific quality control requirements in high-speed laser cladding.
The expansion includes an in-situ camera solution designed for melt pool analysis. This optical system enables high-resolution observation to detect even the smallest deviations within the melt pool during the coating process.
Complementing the optical system is the Powder-Gas Jet Analysis (PGSA) technology. This tool provides a detailed analysis of the powder-gas flow, assessing critical process variables including:
- Nozzle condition
- Focus position
- Powder-laser alignment
Integration into PROMOS Suite
Weldmetrix is incorporating these sensors into its proprietary PROMOS Monitoring Suite. This platform captures, visualizes, and analyzes sensor data in real time to create a unified process map.
The suite combines the new optical and PGSA components with the existing WLDR sensor system, which operates with a sampling rate of up to 5 MHz. By integrating these data streams, the system monitors the following variables simultaneously:
- Temperature and emission
- Layer thickness
- Optical behavior
- Powder flow
Impact on Brake Manufacturing
The expanded monitoring ecosystem is designed to improve early fault detection and process stability for brake manufacturers, Tier 1 suppliers, and OEMs. This approach reduces scrap rates and shortens ramp-up times while ensuring the traceability of every production step.
For production environments typical of the brake industry, the economic impact is significant. Weldmetrix data indicates that for a production volume of approximately 100,000 coated brake discs per year, this holistic monitoring approach can achieve savings exceeding €200,000 annually.
Executive Commentary
Martin Melchart, COO of weldmetrix, explained that the expansion continues the company’s strategy of integrating all relevant process information into a single, intelligent system.
Christian Farmer, CEO of weldmetrix, added that the transfer of these mature technologies demonstrates confidence from both HPL Technologies and Fraunhofer ILT. He noted that customers will now benefit from a more comprehensive and future-proof solution.
Subscribe Today!
Sign up for our weekly eNewsletter and get a free copy of our quarterly digital magazine.
