Over 60 years, A1 Metallising Services has developed expertise in matching repair processes to the specific component requirements. We assess each job on its merits, examining operating conditions, load profiles, material properties and service environment. We can then recommend the right repair solution for the best outcome.
The right solution requires the right toolkit. We ensure our services can meet any challenge, are technologically advanced and deliver the highest standard. That’s why we invested in Precision Power (Hot-Wire) laser cladding technology and became the first workshop in Australia to implement it. It can complement other solutions while also coming with its own powerful advantages.
How Precision Power (Hot-Wire) laser cladding works
Cold-wire laser cladding melts the substrate and filler at the same time. Hot-wire preheats the filler before it hits the melt zone, which reduces heat input and tightens control over dilution. This precision is particularly valuable when working with alignment features or parts machined to close limits.
Laser cladding melts substrate and filler together, creating a single, cohesive structure. The melt pool stays shallow (0.2mm-1.0mm), letting substrate and alloy intermix without a hard boundary. The result is dense, low-porosity metallurgy (i.e., the material’s structure and chemistry) with fewer entry points for corrosion and fewer sites where fatigue cracks form.
Understanding your surface engineering options
Industrial components often need thick wear layers while maintaining tight tolerances. Components such as vertical pump shafts in power generation and water treatment facilities, hydraulic cylinder rods in mining and earthmoving equipment, impeller journals and bearing surfaces all require careful process selection.
We offer a range of proven solutions:
Thermal spray such as HVAF and Twin Electric Arc Spray works efficiently across large areas and handles corrosion, erosion, wear and dimensional rectification exceptionally well. With 60 years of thermal spray expertise and thousands of successful applications, this process forms the foundation of our business and continues to deliver reliable, cost-effective results for the majority of industrial repairs.
Arc welding produces solid fusion and is the right choice for many repair scenarios where robust deposits are needed and heat input can be managed appropriately.
Precision Power (Hot-Wire) laser cladding offers specific advantages for applications requiring thick deposits (3-4mm+) with minimal dimensional change. It complements our other services by handling the subset of repairs where these characteristics are critical.
When Precision Power (Hot-Wire) laser cladding shines
We recently rebuilt a 1.2-metre vertical pump shaft for a major water treatment facility. The component had four critical alignment features and tight tolerance requirements across all journals.
For this specific application, Precision Power (Hot-Wire) laser cladding was the optimal solution. It rebuilt the worn surfaces with minimal heat input, preserving dimensional tolerances. All four journals met original specifications, and the shaft returned to service without vibration issues or premature bearing wear. Laser-cladding components generally machine back to ±0.01mm without issues, which was essential for this repair.
60 years of failure analysis and process selection
After six decades analysing component failures, we know successful repairs depend on accurate diagnosis. Wear tracks, corrosion patterns, process chemistry, load cycles and temperature ranges all guide which process and alloy system will deliver the longest service life.
This is where the breadth of capability creates value. We’re not limited to a single process, so our recommendations aren’t constrained by what we can do, they’re based on what the project requires. Whether that’s Precision Power (Hot-Wire) laser cladding, thermal spraying or welding, it depends entirely on the specific parameters.
Expanding Australia’s surface engineering capability
A1 Metallising Services has built its reputation over 60 years by mastering thermal spray and related surface engineering processes. These remain the cornerstone of what we do, delivering reliable results across the vast majority of industrial repairs.
Adding hot-wire laser cladding, still the only system of its kind in Australia, means we are prepared for anything, even the toughest repair jobs!
With advanced technology, a powerful range of services, and six decades of surface engineering experience our team is equipped for efficient and advanced, high-quality repairs.
If you’re assessing a worn component and need expert guidance on the right repair approach, contact the A1 Metallising Services team. We’ll recommend the solution that fits your specific requirements.
