The Fraunhofer Institute of Laser Technology uses SMaC for both coating and machining

SMaC allows rapid and efficient application of high-strength coating materials and simultaneous machining. Smacs will enable the industry to produce components with longer service lives and longer operating cycles, an advantage that is highly attractive to the energy, transportation and chemical industries. SMac stands for synchronous processing and coating, combining laser material deposition with turning, grinding or milling.

Paints are like invisible champions: barely noticed, but they do great things. They help protect components from all kinds of damage and wear. They improve the physical or chemical properties of the surfaces of components or give them certain functions. They can also help save energy due to their insulating or reflective properties.

A new patented combination process developed by ILT at the Fraunhofer Institute for Laser Technology - Synchronous Processing and Coating (SMaC) - also improves the energy footprint in another way. "We combine machining with extremely high speed laser material deposition EHLA in a single process step," explains Viktor Glushych, head of Fraunhofer ILT's Coating LMD and Heat Treatment Group. "This allows us to reduce processing time significantly," he said. Depending on the required configuration file and coating material, process time can be reduced by more than 60%.

SMaC solves one of the fundamental problems with high-strength protective coatings that resist corrosion and wear: the harder the coating, the better the protection, but the more complex the post-treatment. SMaC is unique in that it takes advantage of the waste heat generated during the EHLA process.

After the laser material is deposited, the coating material shows only a fraction of its hardness due to the presence of residual heat of hundreds of degrees Celsius. In parallel machining, the tool can operate at a higher cutting rate because the coating material is softer when processed immediately after deposition.

"With SMaC, we can economically apply corrosion and wear resistant coatings. We achieve higher surface quality and longer tool life compared to the usual sequential machining, "Glushych explained. The EHLA process can be used to process high-strength coating materials - even high-entropy alloys or metallic glasses, which are difficult to process using traditional methods.

SMaC application program

Smacs allow users to coat components in an efficient, economical, and versatile manner. However, the new process is also interesting from an ecological point of view, as components can remain intact for a significantly longer period of time in use, thus reducing the frequency of replacement. "Smacs decisively extend the service life, operating cycle and maintenance interval of parts, assemblies and the entire machine," Glushych explained. "This increases the raw material and energy efficiency of the components and minimizes machine downtime."

Fewer spare parts means less use of raw materials, less maintenance, and less transportation and storage. For many companies, this means they can work more independently and plan more reliably -- in other words, they achieve greater productivity flexibility. In recent years, for example, some companies have been slowed by long delivery times for functional metal components. SMaC will help counter this trend.

"Smacs are very efficient and can save energy, time and resources," Glushych said, describing the advantages. In principle, the process is suitable for all applications where components are pre-painted and subsequently processed. For example, it can be used to produce anti-corrosion and anti-wear coatings, coatings with hard and soft magnetic properties or to produce extremely durable plain bearing coatings and other functional surfaces.

For example, applications can be found in the energy industry and throughout transportation -- anywhere high-stress, rotationally symmetrical components are needed. For example, in the chemical industry, surfaces must be able to withstand highly corrosive substances. SMaC successfully prevents wear and tear in mining or tools. It is not only applied in many fields, but also in many kinds.

Glushych thinks it's a step ahead: "In the context of the upcoming Euro 7 regulation, EHLA coating of brake discs is considered a very promising solution for reducing particulate emissions during braking. By synchronizing the coating and processing, we can manufacture certain brake disc coatings faster and more efficiently, "he reflected. "Another application we will test is the production of multi-material coatings in battery technology." The scientist is convinced that this new combined process will open up many new applications for laser-based coating technology in the near future.

Source: Laser Net