Results That Speak
Real problems. Real solutions. Documented results. Here's how Aarka Laser has delivered measurable value for customers across industries.
Steam Turbine Blade Repair for Power Plant
Turbine blade erosion on steam turbine rotor — Stage 5/6 blades suffering severe damage, causing reduced efficiency, vibration, and potential equipment failure.
The defective blades were removed and laser cladding was applied to rebuild the blade profiles. This restored aerodynamic integrity and minimized operational downtime.
The blades were restored to like-new condition, ensuring seamless operation and preventing costly turbine replacement.
Mining Drill Bit Refurbishment Program
Drill bits undergo severe wear and tear during mining operations, leading to frequent replacement and substantial downtime, and high operational costs.
The worn bits are rebuilt by depositing new material via laser cladding, followed by precision machining to restore the original specifications.
The refurbished bits performed like new, delivering a 40% reduction in procurement costs, and improved operational efficiency.
Damper Body Restoration for Blast Furnace in Steel Plant
Damper bodies used in blast furnace gas duct and gas cleaning systems were experiencing severe wear and surface degradation due to continuous exposure to high temperatures, abrasive particles, and corrosive process gases. Frequent repairs and replacements resulted in increased maintenance costs and operational downtime.
Aarka Laser restored the worn surfaces using Laser Cladding with Cobalt Grade-6 alloy, depositing a 2.0 mm wear-resistant layer on the structural steel damper bodies. The process ensured precise material deposition, superior metallurgical bonding, and minimal heat-affected zone while preserving the component's dimensional integrity.
The refurbished damper bodies were successfully restored to operational condition with enhanced wear and corrosion resistance, extending component service life while reducing the need for replacement and minimizing maintenance downtime.
8-Blade Hammer Restoration for Sponge Iron Plant
The 8-blade crushing hammers used in a sponge iron plant's DRI pulverizers were subjected to continuous impact and abrasive wear, requiring repair or replacement every 3 days at approximately 50 MT of production. Conventional MMAW hardfacing with a 10 mm cobalt alloy overlay resulted in frequent maintenance and reduced equipment availability.
Aarka Laser replaced the conventional repair process with 2 mm Laser Cladding, restoring the hammer blades using a precision metallurgical coating designed to improve wear resistance while minimizing heat input and preserving the base material. The damaged hammer blades were fully rebuilt and returned to service.
Production trials demonstrated a significant improvement in wear performance and operational life compared with the conventional welding process. The laser-cladded hammer blades exhibited substantially lower material loss and enabled longer production runs before maintenance, improving equipment reliability and reducing maintenance frequency.
Turbine Rotor Journal Refurbishment by Laser Cladding
A steam turbine rotor journal had developed wear and dimensional degradation due to prolonged operation, affecting bearing performance and equipment reliability. Replacing the rotor would have resulted in extended downtime, high procurement costs, and disruption to plant operations.
Aarka Laser restored the worn journal using precision Laser Cladding, depositing a high-performance alloy with minimal heat input. The journal was then precision-machined to its original dimensions, ensuring excellent metallurgical bonding, dimensional accuracy, and compatibility with the existing bearing assembly.
The refurbished rotor journal was successfully returned to service, restoring its original dimensions and operating performance. The laser cladding process provided a durable, wear-resistant surface while eliminating the need for costly component replacement and reducing maintenance downtime.
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