DUROC LASER COATING – FROM HORSESHOE HARDENING TO STABLE INDUSTRIAL LASER CLADDING
How do you create a robust and sustainable laser process in a business where every project is unique? For Duroc Laser Coating, the answer is a combination of deep process expertise, the right technology, and a long-term partnership with an experienced laser supplier, LMI AB.
Duroc Laser Coating’s facility in Luleå
SPECIALISTS IN EXTENDING THE SERVICE LIFE OF METAL COMPONENTS
Duroc Laser Coating AB was founded in 1987 in Luleå through a collaboration with Luleå University of Technology, based on the idea of using lasers to harden horseshoes. From this niche application, the company evolved into a leading provider of laser surface treatment and laser cladding for industrial applications, including roll refurbishment and component manufacturing. The business moved from Umeå to Luleå in 2011 under the name Duroc Engineering and has operated as Duroc Laser Coating AB since 2014.
Duroc Laser Coating (DLC) specializes in strengthening and restoring metallic surfaces locally rather than replacing entire components. The company operates exclusively as a contract service provider and handles everything from new production to repair and rebuilding of worn components.
Using laser-based processes such as cladding, alloying, and hardening, DLC can restore surfaces to their original dimensions while also creating new wear-resistant layers with improved properties tailored to the component. Examples include increased hardness, corrosion resistance, friction performance, impact resistance, and high-temperature properties.
“When we have completed our work, we have often at least doubled the service life at roughly half the cost compared to buying a new component,” says Jan Frostevarg, Technical Manager at DLC.
Customers come from a broad industrial base, including the wood, sawmill, pulp and paper industries, mining, automotive, machine tools, and the energy sector, including nuclear, hydroelectric, and wind power. Components range from small parts measuring only a few centimeters to structures up to 15 meters long and weighing as much as 20 tons.
LASER CLADDING – THE CORE OF THE BUSINESS
Laser cladding is a central part of the company’s operations and enables controlled material deposition with high precision.
The technology provides low heat input, minimizing distortion while creating a strong metallurgical bond between the base material and the filler material. This allows for a wide range of material combinations and advanced solutions, such as reinforced surfaces containing embedded tungsten carbides.
Compared to traditional methods such as plasma or arc welding, laser processing provides:
- Less dilution with the base material
- Faster cooling and improved microstructure
- Lower distortion
- Higher precision and repeatability
Refurbishment stages of a component. Worn component – clad component – fully refurbished component
Achieving consistent quality requires more than just technology.
“It is about material knowledge, process control, and how the equipment is operated. Every material combination requires its own parameters, and fixturing and component handling are equally important.”
THE 2018 INVESTMENT – FOCUS ON CAPACITY AND STABILITY
In 2018, DLC faced a significant technology transition.
Its existing equipment was reaching its limits in terms of both production capacity and maintenance requirements.
“We felt that we were starting to hit the ceiling in terms of efficiency while maintenance demands were increasing.”
As part of a move to new facilities, the company invested in an upgraded production platform based on two high-power fiber lasers.
The requirements were clear:
- Higher output power (7–8 kW)
- A complete system solution including robot integration and auxiliary equipment
- Integrated laser safety
Laser processing on a component with a three-dimensional surface requiring reinforcement
The solution selected was supplied by LMI AB.
“Competence, quality, and pricing were decisive factors. We also had a stable relationship from previous collaborations, which gave us confidence in the decision.”
COLLABORATION AND COMMISSIONING – A STRONG FOUNDATION
Installation and commissioning were carried out in close cooperation with LMI AB.
“The process went relatively smoothly. Laser expertise and an understanding of our business were the most important factors during the startup phase.”
After an expected optimization period, a stable process was achieved relatively quickly, although certain adjustments were required to optimize the system for the company’s specific needs.
“For us, the most important thing was to get equipment that performed the way we wanted. The application expertise itself we have internally.”
TWO 8 KW LASERS – FLEXIBILITY AND ROBUSTNESS
Today, DLC operates two identical 8 kW IPG fiber lasers, providing both redundancy and flexibility in production.
“Having two identical systems gives us robustness in our operations.”
One of Duroc Laser Coating’s two laser cells refurbishing a large wind turbine component
Operational reliability is described as high, which is essential in a production environment where downtime directly affects delivery capability.
The fact that LMI AB serves as both equipment supplier and service partner is considered an important part of the overall solution, particularly regarding access to technical expertise.
A MATURE YET DYNAMIC PROCESS
After more than six years of operation, equipment utilization has reached a high level of maturity. At the same time, DLC’s contract-based business means that processes are continuously evolving.
“We continuously develop new processes because our business is so diverse.”
Once a process is established, a high degree of stability and repeatability is achieved, although occasional variations may occur.
“This can be caused by materials, powder, optics, or gas, but it is usually manageable. We continuously work on quality improvements.”
Operatörsberoendet har minskat över tid, främst genom internt utvecklingsarbete, men kompetensen hos operatörerna är fortfarande avgörande.
SAFETY – A PREREQUISITE FOR THE BUSINESS
Working with high-power lasers places significant demands on safety, and for DLC, laser safety is an integrated part of daily operations.
All operators and process technicians receive laser safety training, and safety-related issues remain a continuous focus throughout the organization.
“Laser safety is a requirement and a prerequisite for our operations.”
The working environment is considered safe thanks to reliable equipment and effective safety systems.
LMI AB has also played an important role through installation, training, onboarding, and ongoing support related to laser safety.
Extended internal optics and powder nozzle mounted on a robot for laser cladding inside narrow geometries. Inspection prior to laser processing.
LONG-TERM PARTNERSHIP AND TECHNICAL CONFIDENCE
Working with the same technology partner over a long period is highlighted as an important factor.
“It is very important to us.”
Although service and logistics can sometimes be challenging due to geographical distance, access to a supplier with deep technical expertise is invaluable when problems arise.
“We manage our processes ourselves, but having the possibility to discuss challenges with a highly competent supplier is extremely important.”
A TECHNOLOGY THAT DEFINES THE BUSINESS
For DLC, laser processing is not simply a manufacturing method—it is the foundation of the entire business.
Our entire business is built around laser processing, primarily cladding, but also alloying and hardening.”
The technology enables longer component life, reduced costs, and improved sustainability for customers, and it will continue to play a central role in the future.
“Laser cladding will remain our primary offering in the years ahead.”
Robot programming prior to cladding a component with a 3D geometry
| FACT BOX – Duroc Laser Coating AB | |
| Company: | | Duroc Laser Coating AB
| Location: | | Luleå, Sweden
| Founded: | 1987 |
| Employees: | |
12
| Industry: | |
Laser Surface Treatment
| LMI Equipment: | |
Two laser cladding cells equipped with two IPG 8 kW fiber lasers and ABB robots
| Installed: | 2018 |
| Result: | |
Controlled material build-up and reinforcement with high precision.
| Website: | https://duroclasercoating.com/ |
