Repair Welding at a Height of 25 Meters

Task
MATEX PM, a company based in Plzen (Pilsen) in the
Czech Republic, markets job-shop solutions for various
metal applications using diode lasers. In the reactor hall of
the Dukovany nuclear power plant a routine check
detected cracks on a gear wheel in the gearbox of a
crane. As the crane was 25 meters up, and there was no
easy way to remove the gear wheel, the customer looked
for another – as simple as possible - solution to repair the
cracks.
Result
The welding was carried out with a Ø 1.2 mm focus
without using any additional filler wire. The mobile diode
laser enabled the gear wheels to be repaired in situ,
avoiding the costly and complex effort of removing them.
A final material test of the repaired gear wheels to the
nuclear power plant’s exact specification was successfully
passed.

Procedure
The repair called for a mobile laser capable of welding the
gear wheels in situ. The laser would have to be compact
and light in order to work on a narrow scaffold. The
Dukovany nuclear power plant contracted MATEX PM to
carry out the repair welding directly on-site using a diode
laser. The LDF 3000-60 mobile diode laser system Material: GS36Mn5
together with a control robot were positioned on a level Task: Weld gear wheels in situ
with the crane at a height of 25 meters in order to weld the Laser: LDF 3000-60
cracks in the gear wheels.
Optic: Focus Ø 1.2 mm
Parameters: 0.6 m/min – Repair welding using a diode laser
Result: Successful repair, the crane is operable again

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