Additive Hardfacing & High-Speed Laser Cladding
Extreme High-Speed Laser Cladding (EHLA) Calculator
Model Extreme High-Speed Laser Application (EHLA) and ultra-fast laser hardfacing. Calculate in-flight powder melting ratio ($\eta_{\text{melt}}$), rotary cladding speed ($v_s = 20 - 200\text{ m/min}$), track thickness ($t$), and helical CAM pitch.
Process & CAM Parameters
Continuous wave fiber laser power in Watts (W).
Rotational component surface speed in m/min (EHLA operates 20-200 m/min).
Co-axial powder mass flow in g/min.
Helical axial pitch overlap percentage (%).
Engineering Calculations
Linear Heat Input (HI)
2.82J/mm
Single Layer Thickness
82µm
In-Flight Melt Ratio
94%
Substrate HAZ Depth
12µm
Dynamic CAM Toolpath & Vector Preview
Need complete manufacturing prepress guidance and formulas?
Read the Full EHLA Prepress Guide →Engineering Principles & Formulations
Extreme High-Speed Laser Application (EHLA) melts metallic powder particles in-flight within the laser beam above the melt pool, rather than melting the base substrate. This allows surface cladding speeds of $20 - 200\text{ m/min}$ (compared to $0.5 - 2.0\text{ m/min}$ for conventional laser cladding), reducing heat input by $90\%$ and shrinking the heat-affected zone (HAZ) to $< 20\,\mu\text{m}$.
Key governing equations:
- Linear Heat Input: $$HI = \frac{P}{v_s} \quad [\text{J/mm}]$$ (EHLA achieves ultra-low heat input of $2 - 8\text{ J/mm}$, replacing toxic hard chrome plating on hydraulic rods).
- Layer Thickness: $$t = \frac{\dot{m}_{\text{powder}} \cdot \eta_{\text{catch}}}{\rho \cdot v_s \cdot S_p}$$ where $\eta_{\text{catch}} \approx 85-95\%$.