Restoring Rotor Sliding Surface of D415 Generator Using Laser Cladding Technology

The rotor sliding surface is one of the most critical areas in the structure of a generator. This surface is subject to significant friction with the bearing and requires high precision in both dimensional tolerance and surface smoothness. Over time, it is prone to wear and scratches, leading to loss of concentricity, increased vibration, and reduced system lifespan.

At Phuong Dong Industry, the restoration process is performed using Laser Cladding technology, applying a suitable alloy powder tailored to the rotor’s working conditions and operating environment.

Technical Challenges – Confined Space & Difficult Welding Angle

• The rotor sliding surface is located deep inside the rotor body, with extremely limited and obstructed access.
• The welding position is at a 90-degree angle to the rotor axis, making it difficult for standard welding heads to reach or maintain precise direction.
• The rotor’s large size and heavy weight require specially designed fixtures to safely hold and align the part.

Technology Solution

• Select a compact and suitable laser welding head for narrow spaces and 90-degree welding angles.
• Design a custom fixture system for secure clamping and precise alignment of the rotor.
• Use wear-resistant and heat-resistant alloy powder appropriate for the operating environment.
• Control the welding process with a CNC system to ensure accuracy and uniformity of the cladded layer.

Advantages of Laser Cladding

• Minimal heat distortion due to low heat input and a small heat-affected zone.
• Metallurgical bonding between the coating and base material, with no cracks or porosity.
• Precise control over the cladding layer’s thickness as per design.
• Rapid restoration without altering the base material’s structure.

Results After Restoration

• The rotor sliding surface meets the required standards for roundness, surface roughness, concentricity, and hardness.
• Improved equipment stability, reduced vibration, and extended bearing and rotor lifespan.
• A cost-effective and time-saving solution compared to full replacement.

✅ Restoring the rotor sliding surface of the D415 generator under tight space and challenging welding conditions is a prime example of applying modern technology in industrial maintenance.
The use of a suitable laser welding head, custom fixture, and optimized alloy powder delivered effective, safe, and sustainable results.

Contact Us for Technical Consultation and Service:

PHUONG DONG INDUSTRIAL  AND TRADING CO., LTD
Address: Alley 70, Dan Di, Uy No, Dong Anh, Hanoi
Phone/Zalo/Whatsapp: +84 987 822 360