Stop replacing cast iron parts and start 3D repairs with coaxial laser processing
Why focus on cast iron repair?
Cast iron continues to play a vital role in components such as machine parts, gearbox housings and hydraulic units – across industries from agriculture and mining to utilities, construction, transport, retail and hospitality. Its high stiffness, corrosion resistance and damping capacity make it a cost-effective material.
But when it comes to maintenance, cast iron quickly becomes a challenge:
- high susceptibility to cracking
- difficult heat input control
- often no cost-effective alternative to new production
This is exactly where OSCAR-PLT’s laser-based repair approach comes into play.
From 26 to 28 August 2025, OSCAR-PLT will attend the Nordic Laser Material Processing Conference (NOLAMP) for the first time. The event is one of Europe’s most important gatherings for laser-based manufacturing and repair technologies.
With a practice-driven talk on the additive repair of cast iron components, OSCAR-PLT will present its ProFocus technology – and a highly relevant solution for many industrial maintenance challenges.
Talk: Additive repair of cast iron materials using coaxial laser wire cladding
1 Feeding lance
2 Wire nozzle
3 Inert gas cap
4 Laser beams
5 Filler metal (wire or powder)
The focus of the NOLAMP presentation is the application of OSCAR-PLT’s ProFocus technology for precise and resource-efficient repair of cast iron components – without the need for preheating.
The presentation highlights:
- selection of suitable filler materials (e.g. NiTi4, quEISI®)
- development of stable process parameters (laser power, wire feed)
- two real-world case studies from industrial maintenance
It’s time to shift from replacement to repair. Our studies show that a wide range of materials – including GJS and GJL grades – can be reliably repaired using our ProFocus technology: crack-free and without time-consuming preheating.
— Ulf Jasnau, customer project lead & sales engineer at OSCAR-PLT
The technology behind it: ProFocus
The patented ProFocus optic was developed specifically for coaxial wire-based cladding and has proven itself in industrial use since 2019. Its ring-shaped laser beam delivery enables direct energy input into the filler metal, drastically reducing the heat-affected zone on the base material.
Key technical advantages at a glance:
- No preheating or postheating required
- Fully automated, robot-guided welding process
- 100% wire utilisation, no powder loss
- Free choice of wire materials
- High precision
Case study 1: Repairing a cast iron housing
The gearbox housing, made of EN-GJS-400-18-8-LT, showed deep cracks along the flange surface. The repair was completed in four steps:
- Milling out the damaged area (up to 10 mm depth)
- Cladding with NiTi4 wire – no preheating, directly on base material
- Layered build-up with 12 layers, total of 2.3 kg wire
- Non-destructive testing (PT): no cracks, no delamination
The full repair was carried out under near-industrial conditions on a full-size component. The result: full compliance with dimensional and surface quality requirements.
Case study 2: Hardfacing of a hydraulic component
A second case involved the hardfacing of a heavily used hydraulic shaft made of EN-GJS-600-3. The issue: damaged chrome coating around the sealing surface; target hardness: approx. 65 HRC.
Approach:
- Specially developed wire by quada V+F® (C 1%, Cr 4%, Mo 8%, V 2%)
- Cladding in spiral path using ProFocus to avoid stop-start transitions
- Result: hardness up to 930 HV0.1, no cracking, excellent bonding
The deposited layer was then ground to final dimensions and successfully PT-tested.
Benefits for industrial users
Additive repair of cast iron using ProFocus technology enables:
- Cost savings through reuse of high-value components
- Time savings through elimination of spare part lead times
- Material savings through precise layer build-up
- CO₂ reduction by extending part lifecycles and reducing new production
- Higher asset availability through rapid on-site maintenance
Looking ahead: additive repair as part of modern maintenance
The techniques presented offer industrial users a field-proven solution for restoring damaged cast iron components in a reliable and sustainable manner. ProFocus wire-based cladding is particularly suitable for applications where high quality standards meet tight maintenance windows.
OSCAR-PLT continues to develop its approach, with a focus on:
- Combining additive processes with milling for automated surface prep
- Expanding wire materials, e.g. cored wires
- 3D repair strategies for complex geometries
Conclusion: cast iron repair pays off
Participating in NOLAMP 2025 is an excellent opportunity for OSCAR-PLT to present its proven solution for additive repair of metallic components to the Scandinavian market. With technology expertise, real-world experience and robust implementation, we support our customers as long-term partners in the future of industrial maintenance.
Want to know more? Get in touch!