Welcome to Harald Dickler - Special Optics for Laser Technology

News
EHLA – Extreme High-Speed Laser Material Deposition with HIGHNO-Powder Nozzle.
© HD Sonderoptiken für die Lasertechnik

WE HAVE MOVED!



MORE ROOM FOR NEW CHALLENGES

Due to our steady growth, our current premises at the Fraunhofer Institute for Laser Technology in Aachen were ultimately no longer able to keep pace. In order to be prepared for the future and to enable further continuous growth, we therefore looked around for new premises during the year and found what we were looking for in Übach-Palenberg.

From 01.01.2021 you can find us at the following address:

Harald Dickler – Special Optics for Laser Technology
F. W.-Raiffeisen-Straße 31A
52531 Übach-Palenberg


PROFILE



Your partner for powder nozzles for EHLA and LMD

The company was founded in 2005 and is based at the Fraunhofer Institute for Laser Technology ILT in Aachen.

We have many years of experience in the development of special optics and tools for laser technology. Here, the focus is mainly on powder supply systems for LMD and EHLA. Due to the close cooperation with our partner Fraunhofer ILT, we are working on reliable, industrial solutions for series production.

We not only offer customer-specific solutions for a wide range of tasks, but also support you with our extensive know-how in application and process development. In addition, we advise you in the selection of suitable nozzle technology and other coating components to increase efficiency. A wide range of powder nozzles are available.

Together with our partners we will find the optimal solution for your application in the field of LMD and EHLA.


NEWS



HIGHNO 5.0W - Coaxial Powder Nozzle with direct water-cooled Tips

Due to the continuous development of laser beam sources with high laser powers for LMD and EHLA, the coaxial powder nozzles (continuous powder feed) with indirect cooling are reaching the limits of their performance. Despite the clear technical advantages, the partially high back reflections limit the possible applications of this nozzle configuration. To reduce this gap, we have further developed our HighNo powder nozzle. With the HighNo 5.0W, HD has created the first coaxial powder nozzle with directly water-cooled nozzle tips. These are also equipped with wear-resistant coatings to increase service life.



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HIGHNO 5.0W

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HIGHNO 5.0W - Nozzle tips module





DISCRETE POWDER NOZZLES

HD offers with the discrete powder nozzle "HighNo - 6" a robust solution for additive manufacturing with high deposition rates. Here, 6 powder gas streams, guided coaxially to the laser beam, generate a powder focus, which enables the application of 3D contours even in constrained positions. Due to the direct water cooling and the large nozzle distance (20 mm) an application at large laser powers (up to 20 kW) is possible. Therefore it is not sensitive to back reflections or flying particles. The modular design of the nozzle allows the use of wear-resistant precision tubes (inlays) of different dimensions for variable powder gas beam focuses. Depending on the application, this allows in particular larger powder mass flows and consequently thicker and wider layers to be applied. Customer-side replacement of wear parts (e.g. inlays) and adaptation to different processing optics is possible at any time.



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Discrete Powder Nozzle HIGHNO 13 - 6 (Standoff: 13 mm)

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Discrete Powder Nozzle HIGHNO 20 - 6 (Standoff: 20 mm)





PRODUCTS




Powder Nozzles


Rapid-Powder-Switch


Powder Distributor


Adjustment Unit


Beam Guiding Systems


Cardanic Deflector

APPLICATIONS



ENVIRONMENTAL POLLUTION FROM BRAKE DISCS

According to the Federal Environment Agency, the largest proportion of fine dust in traffic (approx. 60%) comes from abrasion of brakes, tires and the road. Technical solutions to reduce environmental pollution are still being tested or are not available. Expensive ceramic techniques are used for more wear-resistant tires and brake pads due to the lack of cheap alternatives. But the situation with the brake discs looks much more problematic, because there is no alternative to its manufacturing. There is no economical and above all environmentally friendly replacement. In particular due to the high loads in operation, they are one of the most stressed components on the car. Cast iron with embedded graphite is predominantly used here, but the price-performance ratio has so far justified the use of this material - despite the undisputed disadvantages.


However, this inexpensive material leads to high fine dust emissions during operation and therefore represents an immense environmental burden. The widespread coating processes such as electroplating or thermal spraying proved unsuitable as they cannot effectively protect the brake discs.

  • No metallurgical bonding on cast iron
  • Brittle phases, pores and cracks in the coating or connection zone
  • A considerable amount of material (approx. 50% powder efficiency) and costs involved


EHLA AS A SOLUTION FOR REDUCING FINE PARTICULATE EMISSIONS

The special process control in the EHLA enables the production of low-wear brake discs:

  • Metallurgical bonding on cast iron
  • No flaking off of the layers as with conventional methods
  • Free of pores and cracks in the layer
  • Very low thermal impact and thus reduced distortion of the component
  • Efficient and long-term protection of brake discs

This type of process control enables quick and economical coating of wear and corrosion protection layers for the first time. This leads to a drastic reduction in the environmental impact of fine dust:

  • Less brake dust ⇒ up to 90% reduction in emissions from fine dust
  • Fewer disc changes by increasing the service life ⇒ service life over the entire car life cycle
  • Use of environmentally friendly materials
  • Low consumption of resources (approx. 90% powder efficiency)
  • Saving valuable resources through thin layers
  • Less post-treatment
  • Innovative material combinations possible


Link: Press release "New Fraunhofer coating process provides effective protection for brake discs"




Coating of a brake disc by EHLA with HighNo - Powder Nozzle

The video shows a brake disc which is coated by "Extreme High-speed Laser Material Deposition". This coating technology enables the economical production of low-wear brake discs with significantly reduced fine dust emissions.


TECHNOLOGY




EXTREME HIGH-SPEED LASER MATERIAL DEPOSITION KNOWN BY ITS GERMAN ACRONYM EHLA

The EHLA process is a patented and award-winning process from the Fraunhofer-Institute for Laser Technology in Aachen. This is a revolutionary approach for the production of corrosion and wear resistant layers. This process is a further development of conventional laser cladding (LC), in which the innovation of the process method is defined by

  • complete melting of the powder through targeted interaction of radiation and powder particles above the melting bath and
  • apply in liquid form to the component surface.

Compared to conventional LC, higher process speeds and consequently higher coating rates are possible. Coatings can now be produced faster and more economically, while maintaining the decisive quality features of conventional LC (including metallurgically bonded layers without pores and cracks). The following pictures show the technological and economic advantages of the EHLA-process, which finally enable the process to be used in a large-scale production.



PDF: EHLA: Extreme High-Speed Laser Material Deposition

PDF: Coating hydraulic cylinders by EHLA © Fraunhofer ILT

PDF: Certified coatings with the EHLA process© Fraunhofer ILT

PDF: Powder Nozzle for EHLA Process© Fraunhofer ILT


AWARDS FOR EHLA PROCESS

The team from the Fraunhofer-Institute for Laser Technology has received several awards for its work in developing an alternative to chrome plating:

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Steel Innovation Award 2018

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Berthold Leibinger Innovation Award 2018

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Joseph-von-Fraunhofer Award 2017



LASER MATERIAL DEPOSITION

Laser material deposition or also known as cladding is one of the generative manufacturing processes. Here, a filler material in powder form is injected through a powder nozzle into the molten bath generated by the laser beam on the component surface and melted there. By moving the laser beam or the coating optics relative to the component and overlapping individual tracks, a layer is created on the component. The maximum process speeds achieved here are around 15-20 m / min. The main process features are:

  • high-precision, automated application of layers with thicknesses from 0.1 millimeters to several centimeters
  • metallurgical bonding of the layer with the base material (free of pores and cracks)
  • low heat input into the substrate
  • No penetration notches / undercuts
  • High flexibility thanks to a large selection of same and different compositions
  • Machining of almost all metallic alloys possible
  • High reproducibility
  • Little post-treatment due to close-contour layer application

PDF: Laser Technology for Repair and Functionalization© Fraunhofer ILT

SERVICE



  • Feasibility studies / process development
    • Laser cladding (inner and outer contours)
    • EHLA – Extreme High-speed laser cladding
    • Laser cutting
    • Laser welding
    • Laser hardening
    • Laser soldering
  • Advice and recommendation of suitable powder nozzles for the respective application
  • Development / modification of powder nozzles on customer request
  • Training

PARTNER/CUSTOMER



CONTACT

To contact us please send an E-Mail.

HD Sonderoptiken für die Lasertechnik

F. W.-Raiffeisen-Straße 31A
52531 Übach-Palenberg

+49 2451 6169 989
+49 2541 6169 988
info@harald-dickler.de

Office Hours

Monday - Friday: 9 AM - 5 PM