Cost comparison of 8KW laser cladding vs traditional PTA welding for large repairs

Overall Cost Structure

For large-scale repairs on shafts, axles, or turbine components, both 8 kW laser cladding and PTA (Plasma Transferred Arc) welding can restore worn surfaces. PTA generally has lower equipment and consumable costs, but 8 kW laser cladding offers higher precision, reduced distortion, and lower rework rates. When total lifecycle cost is considered—including machining, downtime, and service life—laser cladding often becomes more economical for high-value components in sectors such as power generation and oil and gas.

Material and Machining Costs

PTA welding typically produces thicker, less precise overlays with a larger heat-affected zone. This often requires heavy stock removal and longer finishing cycles via CNC machining, increasing cycle time and tooling wear. Laser cladding delivers narrower beads and better dimensional control, which reduces added thickness and machining allowance. For large repairs, the savings in machining hours and cutting tools can offset the higher hourly cost of the laser system.

Rework Rate and Defect Cost

PTA overlays can suffer from higher dilution, cracking, and porosity if parameters are not tightly controlled, especially with demanding superalloys such as Inconel 718 or cobalt-based Stellite 6. Laser cladding’s controlled energy input and smaller melt pool improve bonding quality and reduce defect rates, which directly lowers scrap and rework cost. When combined with material testing and analysis, laser-cladded repairs achieve more consistent quality for critical rotating parts.

Lifecycle and Downtime Economics

From a lifecycle perspective, laser-cladded layers generally show better wear and corrosion resistance when high-performance alloys (e.g. Hastelloy, Stellite) are applied with low dilution. This extends overhaul intervals for components used in marine and mining applications, cutting long-term maintenance and shutdown costs. In contrast, PTA may appear cheaper per hour but often leads to shorter service life and more frequent rework.

When PTA Remains Competitive

For non-critical components, moderate loads, or low-value parts, PTA can still be the more economical choice due to its lower process cost and simpler setup. However, for high-value superalloy components where downtime and failure risk dominate the cost structure, 8 kW laser cladding usually offers a more favorable cost-to-performance ratio.