Pusty, Tomasz; Kojro, Radosław; Kosiuczenko, Krzysztof
(Scientific Journals Maritime University of Szczecin, Zeszyty Naukowe Politechniki Morskiej w Szczecinie,
)
This study evaluates the quantitative effects of laser cladding technology on the refurbishment of valve cages
and exhaust valves in a Deutz TBD645 internal combustion engine. Laser powder cladding with Inconel 625
alloy is applied to GGG40 cast iron, and process parameters are optimized to minimize Fe dilution. The method
enables low dilution, a homogeneous crack-free microstructure, reproducible valve seat geometry, and stable
surface roughness after machining. Quantitative results indicate that laser cladding reduces unit repair costs
by 70–80%, while total overhaul expenses decrease by 40–60%. For exhaust valve refurbishment, yearly savings of EUR 125,000–200,000 are achievable for fleets repairing 50–80 components per year. Despite process
costs of EUR 250–383/kg, economic benefits remain strongly positive due to reduced downtime and extended
component lifetime. The results confirm that laser cladding is an effective method for marine engine overhauls,
delivering measurable economic benefits and supporting circular economy objectives in line with IMO 2030
and EU Green Deal targets.