The Metalplus Division is a leading provider of engineered repair technologies for critical rotating machinery and its essential components for assets up to 200MW, recognised for its commitment to innovation and quality. As a division of ACTOM, the well-established South African engineering firm, Metalplus specialises in advanced repair solutions, providing high-quality products and services across power generation, petrochemical, mining, rail transportation, and paper.
In a move to improve its in-house product portfolio and production efficiency, Metalplus has acquired a new Robotic Laser Welding Unit. This newly refined technology represents a significant advancement in welding capabilities, heralding a new era of precision weld repairs that no other available technology can achieve. With full production control and scheduling, we see a reduction in logistical delays, meeting our clients’ ever-pressing repair turnaround times for their operations and service-level requirements to address the increasing trend of breakdown repairs.
Modern Welding Technology
The Robotic Laser Welding Unit at Metalplus is designed to cater for extremely small shaft repairs to large 30t rotors, with advanced programmable eight-axis robotic positioning and rotational control seamlessly integrated with the laser welding system. Recent innovations in laser sources, laser optics, and filler material delivery systems make this modern technology endlessly adjustable for Metalplus to develop the exact parameters for the repair application at hand, with astonishing quality results and superior mechanical properties of the weldments.
According to Roman Mornau, General Manager of Metalplus, “ the standout feature of this unit is its ability to weld without distortion while producing perfect fusion with the smallest possible heat-affected zone and a resulting deposited metal crystal structure that inhibits crack initiation and crack propagation. Laser welding provides benefits in all aspects of welding.”
The Robotic Laser Welding Unit employs fusion welding of metals by delivering a high-energy focused laser beam to create a minute melt pool on the surface of the base material. It fills this pool with micron-sized metal alloy powder particles to fuse and add material volume. Fusion welding is used to produce strong, durable welds that surpass metal spraying applications, with welding powder alloy compositions engineered specifically for repair and, if desired, to increase the strength of the repaired component. The robotic system’s ability to precisely guide the small melt pool to achieve a uniform cladding layer and controlled metal build-up is essential to the operation.
The development of our high-standard welding for a variety of materials to be repaired has been approved by international welding engineers and SANAS-accredited metallurgical laboratories. All our welding is qualified by our ISO 3834 integrated quality management system together with our ISO 9001, 14001 and 45001 accreditation. Laser welding results in a superior structural integrity, essential for the demands of the repaired component.
Industry Applications
The versatility of the Robotic Laser Welding Unit makes it suitable for a range of repair applications for industrial machine components constructed from high temperature steel, corrosion-resistant steels, high-strength and high-impact-resistant steels. It addresses the growing demand for precision welding to achieve reliability, where traditional methods are inadequate. “By applying our new Robotic Laser Welding unit in our internal repair processes, our turnaround time has decreased by weeks and on larger projects by months, which enables us to ensure our clients’ facilities do not experience long downtimes,” Roman added.
Future Prospects
Metalplus is dedicated to innovation and sustainability, and this new robotic unit aligns with the company’s strategic vision of adopting cutting-edge technology to meet its customers’ changing needs. With continuous advancements in automation and artificial intelligence, the future of welding appears brighter than ever.
As industries seek greater efficiency and productivity, Metalplus’ Robotic Laser Welding Unit is poised to be of great significance in extending the operating life of installed machinery, showcasing the division’s commitment to quality and excellence in repair processes. By investing in such technologies, Metalplus not only enhances its market position but also supports the wider move towards smart manufacturing.
Metalplus’ Robotic Laser Welding Unit offers promising solutions that can bring transformative changes to their production processes.