Supersize repair welding  

Industry faces major challenges when it comes to the maintenance of large components. As this case study shows, additive repair creates attractive economic opportunities: Mining companies are already saving several 100,000 Euros per year.

OSCAR-PLT’s ProFocus laser technology has been on the market since 2019. Since then, it has proven its reliability in industrial use, time and again. A complete turnkey system from OSCAR-PLT, the ProFocus Laser Cell, has also been available since the end of 2023 – another pioneering tool for additive repair.

Case study: repair welding in open-cast mining

A current example of the capabilities of the ProFocus system is the repair of bearing shells in the bucket wheel gearbox of open-cast mining excavators. The components, which weigh several tonnes and measure 4 x 2.5 x 4 m³, are welded directly onto the worn area thanks to the flexible robot-guided positioning of the laser head.

In the past, the time required per repair was up to 180 hours, as housing bores had to be laboriously joined with bushes and spindled out. With ProFocus, the turnaround time is now only around 40 hours.

Michael Schnick, Managing Director of Oscar PLT, comments: ‘Our aim is to work with our customers to redefine the limits of what is possible in additive repair.’

Results at a glance

Additive repair with ProFocus offers clear advantages for maintenance, and not just in open-cast mining. Large components can also be repaired efficiently, cost-effectively and reliably in other branches of industry. In addition, the service life of machine components is extended thanks to new material combinations and the associated mechanical and tribological improvements.

Automated control

A key element of the ProFocus line is its user-friendly operating system. HDR cameras provide detailed images of the welding process and enable seamless process control and regulation. Automatic correction of the working distance ensures maximum precision.

Sensors guarantee permanent contact between wire and component, and prevent the melt from breaking off. Infrared cameras recognise local hotspots and control the optimum application of heat to the component to be repaired.

OSCAR-PLT’s ProFocus technology not only provides solutions for current challenges in additive manufacturing, but also a vision for future business models. With comprehensive advice, preliminary tests, training and agile technical support, OSCAR-PLT stands by its customers as a long-term partner.