Jun. 05, 2025
Machinery
Laser spot welding is a welding technique that utilizes a focused laser beam to create welds in small and localized areas. The laser spot welding process involves directing a high-energy laser beam onto the workpiece, causing the metal to melt and form a weld. The focused laser spot delivers a high power density, resulting in rapid heating and localized melting of the metal. The molten material solidifies to create a weld joint that is strong and reliable.
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Laser spot welding offers several advantages. Firstly, it allows for high precision and accuracy, making it suitable for welding delicate or small parts. Laser spot welding uses a concentrated beam, typically ranging from 0.1 mm to 2 mm in diameter, to perform precision welds in highly localized areas. The small heat-affected zone reduces the risk of distortion or damage to the surrounding material. Additionally, the non-contact nature of laser spot welding minimizes the chance of contamination or surface marks on the workpiece.
Laser spot welding is utilized in a wide range of applications across various industries. One common application is coil welding, particularly in electronics and electrical engineering, in which sub-100-micron spot welds are required. Laser spot welding is also utilized in the medical field for manufacturing medical devices and implants.
Keyhole laser welding is an advanced welding technique that involves the formation of a keyhole, or a deep, narrow hole, in the workpiece during the welding process. This technique utilizes a high-power laser beam to create a focused and intense heat source, which vaporizes the metal and forms the keyhole. The keyhole extends through the full thickness of the workpiece, allowing for deep penetration welding. The keyhole is stabilized by the vapor pressure of the evaporated metal, which supports the cavity walls and prevents collapse during welding.
Keyhole laser welding offers several advantages. It allows for deep penetration into thick materials, making it suitable for welding applications that require strong and fully penetrated welds. The high-power laser beam and focused heat source result in rapid melting and solidification of the metal, leading to fast welding speeds and high productivity. Keyhole laser welding also produces weld joints with minimal distortion and excellent weld quality.
This welding technique is commonly used in industries such as automotive, aerospace, and manufacturing. It is particularly useful for joining thick components and materials, such as structural elements in the aerospace industry or heavy machinery components in manufacturing.
Laser seam welding is a welding technique that utilizes a laser beam to create a continuous and highly precise weld along a seam or joint between two or more metal workpieces. The laser beam is typically focused onto the workpiece using lenses, though mirrors may also be used for beam delivery and redirection. The high-energy laser beam rapidly heats and melts the metal, forming a narrow and well-defined weld pool along the seam. As the laser beam moves along the joint, the molten metal solidifies, creating a strong and continuous weld joint.
Laser seam welding provides high precision and control, allowing for accurate and consistent welds along the entire seam. The focused laser beam enables the welding of thin and delicate materials without causing distortion or damage. Additionally, the high speed of laser seam welding allows for efficient production rates.
This welding technique finds applications in the automotive, aerospace, electronics, and manufacturing industries. In the aerospace sector, it is employed for welding aircraft components, such as fuel lines and structural elements. Laser seam welding is also utilized in the electronics industry to create hermetic seals in electronic packages, as well as in the manufacturing industry to produce various metal assemblies.
Remote laser welding (RLW) is a specialized technique in which the laser beam is delivered through fiber optics and directed onto the workpiece using remote beam steering systems, such as galvo mirrors. Unlike traditional setups that require close proximity between the laser head and workpiece, RLW enables welding operations to be performed at a distance.
In RLW, the laser beam is transmitted through flexible fiber optic cables, allowing for greater flexibility in positioning the workpiece and the welding equipment. This remote operation offers several advantages, including enhanced accessibility to difficult-to-reach areas or complex geometries. RLW is commonly used in industrial applications when the workpiece is large, bulky, or requires precise manipulation.
CO₂ laser welding is a welding process that utilizes a carbon dioxide (CO₂) laser beam as the energy source to join metal components together. It is a widely used and established welding method in various industries due to its versatility and effectiveness.
In CO₂ laser welding, the CO₂ laser beam is generated by exciting a mixture of carbon dioxide, nitrogen, and helium gases. The laser beam is then focused onto the workpiece using mirrors and lenses to create a concentrated heat source. The intense heat generated by the laser beam melts the metal at the welding joint, allowing it to fuse and form a strong weld.
CO₂ laser welding offers several advantages, such as precise control over the welding process due to the focused and well-defined laser beam. This allows for high-quality and accurate welds, even in intricate or delicate components. CO₂ lasers can achieve deep penetration in non-reflective metals like steel, making them suitable for applications that require strong, full-penetration welds, although they are less effective on highly reflective materials like aluminum and copper.
CO₂ laser welding finds applications in various industries, including automotive, aerospace, electronics, and manufacturing. It is commonly used for joining components such as body panels, chassis parts, exhaust systems, and electrical enclosures. CO₂ laser welding is versatile for many metals, particularly carbon steel and stainless steel, though welding reflective metals like aluminum can be challenging and may require surface treatment or assist gases to improve absorption.
Pulsed laser welding is a welding technique that utilizes laser pulses to join metal components together. It is a variation of laser welding in which the laser beam is emitted in short pulses rather than being continuously applied, typically ranging from microseconds to milliseconds in duration. Each pulse delivers a high peak power of energy to the workpiece, rapidly heating the metal and causing it to melt. The pulses are separated by intervals of no laser emission, allowing the material to cool and solidify partially before the next pulse is applied.
The key advantage of pulsed laser welding is the control it provides over the heat input and the resulting weld. The pulse duration, pulse frequency, and energy level can be adjusted to control the amount of heat transferred to the workpiece precisely. This allows for better control over the welding process, especially for delicate or heat-sensitive materials, as it minimizes the heat-affected zone and reduces the risk of distortion or material damage.
The applications of pulsed laser welding are diverse. It is widely used in industries such as automotive, aerospace, electronics, and medical devices. Pulsed laser welding is suitable for joining thin sheets, fine wires, small components, and reflective or thermally conductive materials that are difficult to weld using continuous lasers. It is employed for welding applications in which precision, control, and minimal heat input are critical.
Laser-hybrid welding is an advanced welding technique that combines the advantages of laser welding and arc welding to create a highly efficient and precise joining process for metal components. It involves the simultaneous use of a laser beam and an arc welding method, typically gas metal arc welding (GMAW), although plasma arc welding (PAW) may also be used in some setups.
In laser-hybrid welding, the laser beam acts as the primary heat source, delivering a concentrated and intense energy beam to the joint. The laser beam rapidly heats the metal, causing it to melt and form a weld pool. At the same time, an arc welding process, most commonly GMAW, is employed to supply the filler material, assist in gap bridging, and add supplemental heat to stabilize the weld pool.
The combination of laser and arc welding in laser-hybrid welding offers several advantages. The laser beam provides a precise and localized heat source, resulting in deep penetration and fast welding speeds. It also contributes to reduced distortion, improved control over the welding process, and enhanced joint quality. The arc welding method complements the laser by providing filler material, shielding gas, and additional heat, resulting in better control over the weld pool and improved metallurgical properties.
Laser-hybrid welding finds applications in various industries, including automotive, aerospace, shipbuilding, and heavy equipment manufacturing. It is commonly used for joining thick materials, large structures, and complex geometries. The process is particularly beneficial when high welding speeds, deep penetration, and superior weld quality are required.
Conduction mode laser welding refers to a thermal welding regime in which the laser energy heats the material below the threshold required to form a keyhole, relying on surface melting and heat conduction for joint formation. It is commonly used for welding thin materials or precision components where minimal penetration and a small heat-affected zone are desired.
In conduction laser welding, a laser beam is directed onto the joint between the metal components. The laser beam's energy is absorbed by the workpiece, causing localized heating. As the heat spreads through the material, it conducts along the joint, gradually melting the metal and forming a weld.
The key characteristics of conduction laser welding are the relatively low laser power and longer interaction time with the workpiece. The laser beam's energy is adjusted to a level that allows for controlled heat conduction along the joint without excessive melting or vaporization. This helps minimize distortion and heat-affected zone size, making it suitable for welding thin or delicate materials.
Conduction laser welding offers several advantages. It provides precise control over the welding process, as the heat conduction allows for gradual and controlled melting of the metal. The process produces welds with minimal porosity and reduced risk of defects. It is also less prone to spattering compared to other welding techniques.
This welding method finds applications in various industries, including electronics, medical devices, and jewelry manufacturing. It is commonly used for joining components with thin walls or dissimilar materials that require precise and controlled welding without compromising their structural integrity.
Nd:YAG laser welding is a welding technique that utilizes a solid-state laser known as a neodymium-doped yttrium aluminum garnet (Nd:YAG) laser to join metal components together. It is a widely used laser welding method known for its versatility and capability to weld a variety of materials.
In Nd:YAG laser welding, the Nd:YAG laser generates a high-energy laser beam that is focused onto the joint between the metal components. The laser beam rapidly heats and melts the metal, creating a weld pool. As the laser beam moves along the joint, the molten metal solidifies, forming a strong and continuous weld.
Nd:YAG lasers emit light at a fixed wavelength of 1,064 nanometers, which is well-suited for welding metals such as stainless steel, aluminum, copper, and other alloys. The Nd:YAG laser beam is applied to the workpiece using fiber optic cables or articulated robotic arms, offering flexibility in positioning and access to the weld joint.
Nd:YAG laser welding offers several advantages. It provides precise control over the welding process, allowing for high-quality welds with minimal heat input and reduced distortion. The high power density of the laser beam enables deep penetration welding, making it suitable for thick materials. Nd:YAG laser welding offers precise control over power, pulse duration, and beam profile, making it especially well-suited for pulsed-mode operation. Laser beams can emit pulses with varying wavelengths, and not all of these reach the intended target. As a result, some of the energy is dissipated as heat.
This welding method finds applications in various industries, including automotive, aerospace, electronics, and medical devices. It is commonly used for joining components such as sheet metal, tubes, and other intricate parts. In the aerospace industry, Nd:YAG laser welding can be utilized for joining thin and lightweight materials in the construction of aircraft structures. The focused laser beam ensures accurate and controlled welding, while the minimal heat input helps preserve the material properties. This process allows for strong and reliable welds without compromising the integrity of the aerospace components.
Transmission laser welding of polymers is a welding technique that utilizes laser energy transmitted through a transparent upper component to join two or more polymer parts. It involves the absorption of laser energy by the lower component, typically made of an opaque material, which then generates heat and melts the interface between the parts. The laser beam passes through the transparent upper component with minimal absorption and is absorbed by the lower, opaque component, enabling precise, localized heating at the interface. Once the laser energy is removed, the molten material solidifies, resulting in a strong and reliable weld.
This technique is particularly suitable for joining thermoplastics, as the laser energy can be selectively absorbed by the lower component. The success of transmission laser welding depends on selecting compatible transparent and absorbent materials, as well as optimizing laser parameters such as power, wavelength (typically around 800– nm), and duration.
Transmission laser welding offers several advantages, including precise control, minimal thermal damage to surrounding areas, high welding speeds, and the ability to join dissimilar materials. It is widely used in various industries, such as automotive, electronics, medical devices, and consumer goods manufacturing, in which high-quality and efficient welding of polymer components is required.
Continuous wave (CW) laser welding is a welding technique that utilizes a continuous laser beam to join metal components together. The high-energy laser beam rapidly heats and melts the metal, creating a weld pool. Unlike pulsed laser welding, which uses short bursts of laser energy, CW laser welding emits a continuous beam of laser light throughout the welding process and allows the molten metal to solidify behind it, forming a continuous weld.
CW laser welding offers several advantages. The uninterrupted beam delivers a steady and uniform heat input, resulting in smooth, consistent weld seams with minimal interruptions. The steady heat input enables deep penetration, allowing for the welding of thicker materials. The sustained energy delivery in CW laser welding supports high welding speeds and throughput, making it ideal for high-volume industrial production.
This welding method finds applications in various industries, including automotive, aerospace, electronics, and general manufacturing. It is commonly used for joining components such as sheets, tubes, and structural parts. CW laser welding is valued for its efficiency, reliability, and versatility in producing high-quality welds. In the automotive industry, CW laser welding can be employed for joining body panels or structural components.
Deep penetration laser welding is a technique that uses a high-power density laser beam to achieve substantial weld depths in thick or dense materials. It is specifically designed for welding thick materials or achieving robust weld joints with excellent depth-to-width ratios.
In deep penetration laser welding, a focused laser beam with high power density is directed onto the joint between the metal components. The laser energy rapidly heats and vaporizes the material, creating a keyhole or cavity within the workpiece. The keyhole is formed by the intense laser energy, which causes the metal to vaporize and create a void that extends deep into the material. The laser beam moves along the joint, maintaining the keyhole, and the vaporized material solidifies to form a strong weld.
The key feature of deep penetration laser welding is the formation and control of the keyhole. The keyhole acts as a conduit for laser energy to penetrate deeply into the workpiece, enabling welds with high depth-to-width ratios. The process requires precise control of laser parameters, such as power, focus, and travel speed, to ensure proper keyhole stability and control of the welding process.
Deep penetration laser welding offers several advantages. It enables the welding of thick materials with a single pass, eliminating the need for multiple welding passes or complex joint preparation. This method delivers high welding speeds, strong metallurgical bonds, and a narrow heat-affected zone, minimizing distortion and thermal damage. Deep penetration laser welding is also known for its ability to join materials with high melting points and dissimilar materials.
The application of deep penetration laser welding is found in various industries, including automotive, aerospace, and heavy equipment manufacturing. It is commonly used for welding thick structural components, such as chassis, engine parts, and turbine blades. The process is particularly valuable in applications in which strong and reliable welds with deep penetration are essential.
When it comes to connecting stainless steel components, one of the ideal types of laser welding is typically solid-state laser welding, specifically using an Nd:YAG laser or a fiber laser. Both Nd:YAG and fiber lasers are capable of providing the required power levels and beam characteristics to weld stainless steel effectively. The choice between the two may depend on specific requirements such as power levels, welding speed, or the particular stainless steel grade being used. Stainless steel grades are generally categorized into five main groups: austenitic, ferritic, martensitic, duplex, and precipitation-hardened stainless steels. Each grade has specific considerations and requirements for laser welding. For example, austenitic stainless steels are well-suited for both pulsed and continuous wave (CW) laser welding. Duplex stainless steels generally exhibit good weldability, but it is recommended to perform testing to ensure satisfactory results due to the variety of available materials.
Both CO₂ and Nd:YAG lasers are commonly used for welding thin aluminum sheets, although they have different characteristics and are suitable for different applications. CO₂ lasers are commonly used in industrial applications for welding aluminum. They operate in the infrared range and have a longer wavelength (10.6 micrometers) than Nd:YAG lasers. Aluminum has high reflectivity at the 10.6 µm wavelength of CO₂ lasers, making them less efficient without surface treatments. Fiber lasers or Nd:YAG lasers with shorter wavelengths are better absorbed by aluminum. They provide a high power output and can deliver continuous wave or pulsed beams. CO₂ lasers offer good penetration capabilities, which can be advantageous for welding thick aluminum sections. However, they may also generate more heat, which can potentially cause distortion in thin sheets.
Nd:YAG lasers, on the other hand, operate in the near-infrared range (around 1.06 micrometers). They are known for their high beam quality and can deliver both continuous wave and pulsed beams. Nd:YAG lasers have a shorter wavelength compared to CO₂ lasers, but their absorption in aluminum is still relatively low. This means that Nd:YAG lasers may require additional techniques, like using an assist gas to enhance absorption and improve welding efficiency. Nd:YAG lasers are often preferred for precision welding applications due to their ability to deliver fine spot sizes and high control.
When it comes to laser welding copper components, the most suitable type of laser welding is typically conducted using a solid-state laser, particularly a high-power fiber laser. Fiber lasers operate in the near-infrared range and have a wavelength of around 1.06 micrometers, which is better absorbed by copper compared to other laser types. The higher absorption of the fiber laser enables better energy coupling into the copper material, resulting in improved welding efficiency.
In addition to the laser type, the choice of welding mode also plays a role in copper welding. Continuous wave laser welding, with a steady beam of laser light, is commonly used for copper welding to achieve deep penetration and high-quality welds. Continuous-wave lasers typically result in a keyhole weld. This method has been shown to reduce cracking compared to the constant heat/cool cycle of a pulsed laser, which can exacerbate cracking in copper.
There are several laser types that are appropriate for welding titanium: CO₂, Nd:YAG, and fiber lasers. All of these lasers are effective for titanium welding, and the selection of laser type often balances operational cost with factors such as weld quality, joint accessibility, and thermal management requirements. All these laser types have unique characteristics that make certain lasers more suitable for specific joint configurations and applications. Regarding laser operation, two main approaches exist for titanium welding: pulsed laser welding and continuous wave (CW) laser welding.
Laser welding is a high-precision welding technique that utilizes the intense heat generated by a laser beam to join two or more materials together. It is a non-contact process in which the laser beam is focused on the desired welding point, causing the material to melt and form a bond when it solidifies. The laser beam used in welding is generated by amplifying and directing a highly concentrated beam of light through optical elements.
The key advantage of laser welding lies in its ability to produce extremely precise and controlled welds. The focused laser beam allows for a concentrated heat source, resulting in minimal heat-affected zones and reduced distortion in the surrounding areas. This makes it particularly suitable for welding small, intricate components or materials with high melting points.
The applications of laser welding are extensive across various industries. It is commonly used in the automotive, aerospace, electronics, and medical fields, where precision and reliability are paramount. Laser welding finds application in joining components, sealing hermetic packages, repairing parts, and even in the production of microdevices.
However, laser welding does have some limitations. It requires precise alignment and control of the laser beam, necessitating skilled operators and sophisticated equipment. Moreover, the initial setup cost can be relatively high compared to traditional welding methods.
The purpose of laser welding is to join two or more pieces of material together using a focused laser beam. It is a technique that offers several advantages over traditional welding methods such as arc welding or resistance welding. The primary purpose of laser welding is to create strong and precise welds in a variety of materials and applications.
In laser welding, various types of lasers can be used, depending on the specific requirements of the welding application. The most commonly used lasers for welding include solid-state lasers (such as Nd:YAG and fiber lasers), CO₂ lasers, and, in specific low-power or plastic welding applications, diode lasers. Solid-state lasers use a solid gain medium, such as a crystal or glass, to produce the laser beam. Examples of solid-state lasers used in welding include neodymium-doped yttrium aluminum garnet (Nd:YAG) lasers and fiber lasers. CO₂ lasers are gas lasers that generate a laser beam in the mid-infrared spectrum. Diode lasers produce a laser beam using semiconductor diodes and are typically used in low-power or plastic welding applications due to their limited penetration capabilities in metals.
Laser welding offers several advantages over traditional welding methods. Here are some of the key advantages of laser welding:
While laser welding offers numerous advantages, there are also some limitations to consider, including:
Laser welding finds applications in various industries in which high-quality welds, narrow heat-affected zones, and precise control over the welding process are required. Some common applications of laser welding include:
Yes, laser welding, specifically laser transmission welding, is commonly used to join plastic components. It is a highly efficient, non-contact process particularly well-suited for welding thermoplastics. The specific welding process used is laser transmission welding.
The success of laser transmission welding depends on the selection of appropriate plastic materials. The laser must pass through a transparent or semi-transparent upper layer and be absorbed by an opaque lower layer, which heats and melts at the interface to form the weld. Typically, one component is transparent or partially transparent to the laser wavelength, while the other component is opaque and absorbs the laser energy.
Yes, laser welding is widely used in the medical industry for fabricating and assembling both metallic and polymer-based medical implants and device components. However, it's important to note that the specific welding processes employed in the medical industry can vary depending on the materials and requirements of the implant.
In the case of plastic medical implants, laser welding can be utilized to join various thermoplastic materials. Laser welding is commonly used for orthopedic implants (e.g., hip and knee prostheses), dental implants, cardiovascular stents, pacemaker housings, and precision surgical tools—particularly when biocompatibility and minimal thermal impact are critical.
Yes, laser welding is extensively used in the automotive industry for joining body panels, roof seams, door frames, and battery enclosures, particularly in electric vehicles (EVs). It offers several advantages over traditional welding methods, such as improved precision, reduced heat-affected zone, and faster processing times. There are different laser welding processes employed for automotive body parts, including laser spot welding, laser seam welding, and laser remote welding.
The choice of laser welding process depends on factors such as the material being welded, the joint design, and the desired weld quality. Automotive body parts are typically made of steel or aluminum, and laser welding offers excellent results for these materials.
This article presented types of laser welding, explained them, and discussed when to best use each one. To learn more about laser welding, contact a Xometry representative.
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A laser welding machine is a machine that uses a high-energy pulsed laser or CW lasers to irradiate a workpiece for welding purposes.
It can regulate the energy of the pulsed laser by setting different laser frequencies and pulse widths to weld the workpiece accurately.
Laser welding machines are also referred to as negative energy feedback, laser cold welding machines, laser argon arc welding machines, laser welding equipment, etc.
Its working method can be divided into laser mold welding machines (manual laser welding equipment), automatic laser welding machines, jewelry laser welding machines, laser spot welding machines, fiber optic transmission laser welding machines, vibrating mirror welding machines, handheld welding machines, etc.
Sensor welding machines, silicon steel sheet laser welding equipment, and keyboard laser welding equipment are specialty laser welding equipment examples.
Weldable graphics include points, lines, circles, squares, or any flat shapes drawn by AutoCAD software.
Laser welding machines use the properties of laser light to weld workpieces.
Laser welding involves the radiation of a high intensity laser beam onto a metal surface. Through the laser’s interaction with the metal, the metal absorbs the laser and converts it into heat energy, causing the metal to melt and cool to crystallize to form a weld.
1. Heat conduction welding
When the laser light hits the surface of the material, part of the laser light is reflected, and part is absorbed by the material, which converts the light energy into heat energy and heats and melts. The heat from the surface of the material continues to be transferred deeper into the material in the form of heat conduction, and finally, the two weldments are welded together.
2. Laser Deep Penetration Welding
When a laser beam with high power density hits the material’s surface, the material absorbs the light energy and converts it into heat energy. The material is heated, melted, and vaporized, producing a large metal vapor. The molten metallic liquid is pushed around by the reaction force generated as the vapor flows out of the surface, forming pits. As the laser continues to irradiate, the crater penetrates deeper. When the laser stops irradiating, the molten liquid around the crater flows back, and the two weldments are welded together as they cool and solidify.
It is a new welding method, mainly used for welding thin-walled materials and precision parts, and can realize spot welding, butt welding, lap welding, seal welding, etc.
Laser welding is a fast and accurate technique that uses a high-energy density laser beam as the heat source.
One of the most important laser material processing technology applications is laser welding.
It was mostly utilized for welding thin-walled materials and low-speed welding in the s.
The welding process is of the heat conduction type, i.e., the laser radiation heats the surface of the workpiece, and the surface heat spreads to the inside by heat conduction. The workpiece melts and produces a specified molten pool by manipulating laser pulse width, energy, peak power, and repetition frequency.
It has been effectively utilized for precision welding of micro and small objects due to its unique benefits.
A complete laser welding machine consists of five main parts.
The laser welding mainframe mainly generates the laser beam used for welding, consisting of power supply, laser generator, optical path part, control system, etc.
Some low power lasers are usually built into the automatic laser welding table.
The cooling system keeps the laser generator cold and often supplies a 1-5 HP water circulation chiller.
This system is used to realize the automatic welding function of the laser, which moves the laser beam according to the welding track according to the specific requirements. Generally speaking, there are three forms of motion control:
The entire system is programmed with motion control by CNC programming to control the motion of the table as required. The simplified programming system has the advantage of being easy to operate, requiring no technical expertise or educational foundation, and can be quickly supported and mastered.
Common table systems on the market include:
They all enable precise welding motion control.
Generally speaking, laser welding fixtures are mainly used to hold the welded workpiece in place during the laser welding process and enable it to be repeatedly loaded, unloaded, and positioned for automatic laser welding.
Therefore, the fixture is one of the essential pieces of equipment in laser welding production. Especially in mass production, whether the fixture is designed in place will directly affect production efficiency and output.
In general, the laser welding machine should be equipped with an observation system for real-time microscopic observation of the workpiece, which is used to facilitate accurate positioning during the preparation of the welding program and to check the welding effect during the welding process. In general, it is equipped with a CCD display system or microscope.
High aspect ratio, small weld width, small heat affected zone, small deformation, rapid welding speed, flat and beautiful weld seam, no or simple post-weld treatment, high quality weld seam, no porosity, precise control, small focused spot, high positioning accuracy, and ease of automation.
The laser welding machine has a high level of automation, and the welding procedure is straightforward.
The non-contact operation can meet the cleanliness and environmental protection criteria.
The efficiency of the workpiece can be improved by using laser welding equipment to process it.
The processed workpiece has a beautiful appearance, small welding seam, large welding depth, and high quality.
Laser welding equipment is used for various applications, including dental denture processing, keyboard welding, silicon steel sheet welding, sensor welding, and battery seal cover welding.
However, the cost of a laser welding machine is high, and the assembly accuracy of the workpiece is required. There are still limitations in these areas.
One of the most important characteristics of laser processing is laser power density.
At high power densities, the surface layer can be heated to the boiling point in a microsecond time frame, resulting in a significant amount of vaporization.
Therefore, high power density facilitates material removal processes such as punching, cutting, and engraving.
The surface temperature takes a few milliseconds for low power densities to reach the boiling point. Before the surface vaporizes, the bottom layer reaches its melting point, and a good fusion weld is easily formed.
As a result, the power density in conductive laser welding is between 104 and 106 W/cm2.
The pulse waveform is a critical consideration in welding, particularly plate welding.
When a high intensity beam hits the surface of a material, some energy is lost from the metal surface due to reflection, and the reflectivity varies with the surface temperature.
During a pulse, the reflectivity of the metal varies greatly.
One of the most significant parameters in pulse welding is the pulse width.
It is not only a fundamental metric that distinguishes material removal from material melting, but it also determines the cost and volume of the processing equipment.
Due to the high power density in the center of the spot, the laser focus tends to evaporate into holes.
The power density distribution is relatively uniform in all planes away from the laser focus.
There are two defocusing modes: positive and negative defocusing.
Positive defocusing occurs when the focal plane is above the workpiece; otherwise, negative defocusing occurs.
According to geometric optics theory, when the distance between the positive and negative defocusing planes and the welding plane is equal, the power density on the corresponding planes is approximately the same. Still, in reality, the shape of the melt pool is different.
With negative bokeh, greater penetration is obtained, which is related to molten pool formation.
Laser welding technology has advanced qualitatively due to constant advancements in the field.
Nowadays, laser welding machines have been applied in many fields, such as high-tech electronics, automobile manufacturing, precision machining, etc.
Laser welding is a type of laser application that combines current and traditional technology, yet it has benefits distinct from traditional processing.
1. Good laser beam quality
High power density after laser focusing.
Focused high power low order mode laser with small focal spot diameter.
2. High speed, high depth, and minimum deformation advantages laser welding.
Small holes are produced in the metal material during laser welding due to the high power density, and the laser energy is delivered to the deeper part of the workpiece through the small holes with reduced lateral diffusion.
As a result, the fusion depth of the material is large during the scanning of the laser beam.
It is characterized by high speed and a large welding area per unit time.
3. Laser welding is particularly suitable for welding precise and sensitive parts
Due to its large aspect ratio, small specific energy, small heat-affected zone, and small welding deformation, the laser welding machine is particularly suitable for welding precision and heat-sensitive parts. It can eliminate post-welding correction and secondary processing.
4. High flexibility of laser welding
The laser welding machine can weld at any angle and reach otherwise inaccessible parts.
It can weld a variety of complex welded workpieces and large irregularly shaped workpieces.
It has great flexibility and can achieve welding at any angle.
5. Laser welding can weld difficult materials
Not only may laser welding be used to join heterogeneous metals, but it can also be used to join titanium, nickel, zinc, copper, aluminum, chromium, niobium, gold, silver, and they’re as steel, kova alloys, and other alloys.
6. Laser welding machines have a low labor cost.
Since the heat input of laser welding is very low, the deformation after welding is very small, and very beautiful welding results can be achieved.
Therefore, laser welding has very little subsequent processing, greatly reducing or eliminating the huge polishing and leveling process labor.
7. Laser welding machine is easy to operate
Simple welding equipment, a simple operating method, and ease of learning and use are all advantages of laser welding machines.
Staffing needs aren’t very stringent, resulting in lower labor expenses.
8. Laser welding machine has a strong safety performance
The high-safety welding nozzle can only touch the switch when it comes into contact with metal, and the touch switch detects temperature.
During operation, the unique laser generator has safety safeguards.
To avoid eye harm, laser generator operators must wear protective eyewear when operating.
9. The working environment of laser welding machines is diverse
Laser welding machines can be used in various complex working environments and can be used for welding at room temperature or under special conditions.
In many aspects, laser welding, for example, is comparable to electron beam welding. Its welding quality is slightly lower than that of electron beam welding. However, electron beam welding can only be done in a vacuum, and laser welding technology is more advanced and can be employed in various work settings.
10. Welding systems are highly flexible and easy to automate
However, laser welders also have some limitations.
Due to the high cost of laser holiday related systems.
In addition, laser welding machines require a high degree of precision in installing the welded parts, and the position of the light source on the commercial workpiece must not deviate significantly.
As can be seen, the ten advantages of laser welding machines are far superior to traditional welding methods.
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Laser welding will not be confined to the current state of the art., electronics, automotive, instrumentation, and other areas in the future.
It will also be more widespread in the military and medical fields, especially in the medical field, with a bright future.
Laser welding finds a large number of applications in various types of industries. These industries range from manufacturing to the medical industry to jewelry manufacturing.
Here are a few major industries where laser welding technology is used.
Robotic parts welding would never have become a reality if it weren’t for laser welding technology. The laser beam is aimed at the seam of the part to be welded. A conveyor belt then passes the units to the laser weld.
As a result, the speed at which the process takes place makes it possible to produce welded products quickly. This technology is used in many industries. Almost all manufacturing industries that use metal parts are used for this type of welding. Thus, laser welding has many applications in all types of metal and non-metal manufacturing industries that require welded parts.
The jewelry sector is another key application for laser welding. When it comes to making complicated and delicate jewelry parts from two different materials and fusing them, laser welding technology is ideal.
According to twi-global, almost 15% of all manufacturing processes in the industry involve laser applications in one way or another. CO2-type welding has a large application in the automotive industry. The main applications for welding are found in the manufacture of gears, transmission components, and powertrains.
Circular and toroidal welds are also required in the majority of these goods. As a result, laser welding can also handle circular welds. In addition, Nd: YAG has a high application in welding body parts and automotive structures.
Laser welding has been a great success in the automotive industry, mainly due to the fast, precise, and efficient operation and the low cost in the long run. You can learn more about the application of laser welding in the automotive industry here.
If you started listing the various industries that use laser welding, you would run out of time and writing space, but you wouldn’t run out of industries that use laser welding. Likewise, the medical industry has many applications for laser welding methods.
The largest number of applications of laser welding technology in the medical industry is in dissimilar metal welding. Medical assistive devices are usually made up of different electronic components that are further fitted with multiple semiconductors.
The main challenge of this situation arises when different metals and materials possessing different chemical and physical properties are welded together. However, fiber laser welders have successfully done this job.
Some hard metals and materials, such as stainless steel, 440C or 430, and titanium alloys, are also widely used in the medical industry. These materials are to be welded together with an infallible system to ensure the patient’s health.
Other devices, such as pacemakers, automated external defibrillators, and drug pumps, also utilize laser welding technology.
Before the s, research focused on pulsed laser welding (PW) as high power CW lasers had not yet been developed.
Ruby pulsed lasers were employed in the majority of early laser welding experiments. 1ms pulses had a typical peak output power PM of about 5kW, pulse energy of 1~5J, and pulse frequency less than or equal to 1Hz.
Although the pulse energy was high at the time, the average output power of these lasers was low, which was mostly due to the laser’s low efficiency and the luminous material’s excitation characteristics.
Due to their high average power, lasers soon became the equipment of choice for spot and seam welding after their appearance. Its welding process is carried out by welding joint lapping.
It was not until the birth of continuous power waveform lasers of 1kW or more that laser seam welding with real meaning was realized.
Digital welding machines and digital control technology for dynamic grounding technology of representative works have steadily entered the market as digital technology matures.
Large-scale national infrastructure projects have effectively promoted the development and progress of advanced welding, especially welding automation technology.
The manufacturing of automobiles and parts has increased the demand for welding automation.
The government has steadily promoted the basic welding technology of automatic welding – gas shielded welding to replace traditional manual arc welding since the end of the twentieth century and has shown initial success.
It is foreseeable that automatic welding technology will develop at an unprecedented rate in the future.
In the s, the welding industry to achieve mechanization and automation of the welding process as a strategic goal in developing science and technology in various industries was implemented.
That is, research and development of welding production lines and flexible manufacturing technologies, as well as computer-aided design and manufacture; flux-cored wire grew from 2% to 20%, and submerged arc welding materials will continue to expand at a 10% rate.
Among them, the flux-cored wire has grown faster than solid-cored wire and will overtake solid-cored wire in the next 20 years to become the dominating product in welding centers.
The development of electronics, computer microelectronics, and automation technology has promoted the development of welding automation technology.
In particular, the introduction of CNC technology, flexible manufacturing technology, information processing technology, and other unit technologies have contributed to the revolutionary development of welding automation technology.
(1) One of the fundamental difficulties in welding automation is the intelligence of the welding process control system, which is an essential research direction for the future. We should study the most effective control approaches, such as linear and nonlinear control. The most representative of the welding process are fuzzy control, neural network control, and expert systems.
(2) welding flexibility technology
In future research, we will combine various optical, mechanical, and electrical technologies with welding technology in an organic way to achieve welding accuracy and flexibility.
The use of microelectronics technology to change traditional welding process equipment is the most basic technique to improve welding automation.
The combination of CNC technology and various welding machinery and equipment to improve flexibility is our current research direction.
Our research also focuses on using welding robots and expert systems to achieve automatic path planning, automatic trajectory correction, automatic penetration control, and other services.
(3) The integration of the welding control system integrates people and technology, welding technology, and information technology.
Information flow and material flow is important part of the integrated system. Promoting organic mixing can considerably reduce the volume of data and real-time control requirements.
Attention should be paid to give full play to the human response and judgment in the control and field processing, the establishment of a friendly human-machine interface so that the human and automatic systems are in harmony and unity, which is a factor that should not be underestimated in the integrated system.
(4) Improving the reliability, quality stability, and control of the welding power source, as well as excellent dynamic performance, is also the subject of our attention.
Development of high-performance welding machine, adjust the arc movement, wire feeding, and torch attitude, detect the start of the weld slope, temperature field, molten pool state, and penetration, and provide timely welding specification parameters. We are actively developing computer simulation technology for the welding process to evolve from “technology” to “science,” which is an important aspect of welding automation.
To better satisfy our requirements and achieve faster processes in any work, we must design some corresponding instruments to assist us in completing some operations and saving time and energy.
Great strides have been made in these fields due to the ongoing advancement of technology. Any task in daily life can be automated to a high degree.
Each factory can better improve production and supply efficiency, reduce costs, and gain better operational efficiency.
In the welding process, it is very necessary to choose some good tools to improve the speed of your operation better. And a laser welding machine is a good choice.
For every user, why laser welding machines can achieve better productivity?
As a new energy source, it has a stronger working condition and can complete the effective processing of some materials. In the welding process, certain novel welding methods will be adopted to ensure the welding result and complete each user’s activity in a short amount of time.
People’s living efficiency and working conditions will improve at an increasing rate in the future market. To achieve better production results and meet more users’ requirements, each factory has to continuously improve its technology, achieve more breakthroughs, improve the defects and deficiencies in all aspects, and effectively improve some of the performance that should be improved.
Only constantly from this direction can our products get a better competitive advantage to each user to bring better use effect and achieve effective cooperation between the two sides.
In the welding process, the choice of a laser welding machine is a good choice; it can bring more convenience for manufacturers to achieve higher efficiency. You can complete your work in a set amount of time for each factory in the operation process and, therefore, improve your factory’s operational efficiency. Simultaneously, it is critical to finish the successful welding of several huge tools and improve their process.
If this link isn’t secure, a lot of time and effort could be lost welding some enormous equipment that no one wants to see.
As laser welding technology continues to mature and develop, different configurations of laser welding equipment correspond to different results.
However, is it right to choose the more expensive and better laser welding machine equipment among many companies?
The answer, of course, is no.
So how do you choose the laser welding machine equipment that is the most appropriate?
Only when we understand it clearly, can we know what benefits it has for us. Now let’s talk about the importance of choosing the right laser welding machine!
Before customers choose laser welding machine equipment, the idea is that the chosen laser welding machine equipment can meet my needs, achieve my processing results, and bring me benefits and advantages. Such equipment is what I want.
The price of laser welding equipment, on the other hand, is positioned at the high-end and low-end for laser welding machine makers. High-end equipment can make the processing effect more perfect from the processing effect. A variety of styles, for example, can process a variety of materials, metal and non-metal.
The processing result is excellent as well, although such equipment is expensive.
Is it advisable to go with a high-end laser welding machine?
Of course not. If your material is for non-metallic materials, there is no metal material, and the processing effect is not so great, it is recommended to choose the general one is fine.
Because the more features, the more effective the equipment is, and the more products you process, the more expensive the machine and equipment will be.
In addition, if you buy it without using all its functions, you will spend money on furniture, so it is not worth it.
Only consider what you want to do with this machine and equipment, whether you want to create the same or different products, and then decide based on your requirements.
As a result, only the best laser welding machine equipment should be used.
Suitable means that the businessman’s products can be processed, and the industry with the most applications can meet your requirements. It brings benefits that can meet your requirements. Such equipment is worth more, as opposed to suitability.
If you leave this question alone, you can be sure that a highly efficient and high quality laser welding machine is worth buying!
However, laser welding machines are on the market in the tens of thousands to hundreds of thousands of dollars. A good laser welding machine can double the success rate of your work.
So, what should we consider when determining if a laser welding machine is worth buying?
First and foremost is power.
The laser is the heart of the laser equipment. The higher the power, the more expensive it is.
This is because the higher the power, the more the laser bar and cooling system are needed.
A laser welding machine’s configuration entails a variety of factors.
There are different configurations of laser welding machines for different purposes, such as mold welding machines for welding molds, jewelry welding machines for welding jewelry, vibrating mirror welding machines inside automatic welding machines, fiber optic transmission laser welding machines, fiber optic continuous laser welding machines, etc.
With different equipment configurations, the price is also different.
In addition, the price of an automatic welding machine is generally higher than a manual welding machine because the automatic control system needs supporting automatic configuration, such as a CCD camera monitoring system.
There are also some customization requirements so that the price will be higher.
For example, some production processes require customization of some automatic fixtures, modification of the table, or additional functional accessories.
Laser welding machines must be equipped with workbenches, such as vibrating mirror working method, automatic working method, spot welding working method, and handheld working method. The worktable is non-standard and needs to be designed according to the customer’s product, so the price is not fixed.
Imported products are usually more expensive than domestic imported products, and domestic prices are not balanced.
It’s fair to say that the cost of accessories varies a lot.
The brand also affects the offer.
The brand is also a point that should not be ignored.
Because laser welding devices are sometimes hundreds of thousands of dollars and require a high degree of technology and after-sales service, they must be obtained through formal channels.
Finding manufacturers for direct sales is suggested. Good brands have more mature technology, good product quality, stable performance, and better after-sales service guarantees.
Laser welding equipment is now widely utilized in various fields, including digital products, energy batteries, hardware and plastic, kitchen and bathroom, mechanical manufacture, precision electronics, and artisan jewelry.
There are different brands of laser welding machines, but the structure is similar. What is the difference between various laser welding equipment?
Reasons for laser welding equipment brand pricing differences.
Laser welding equipment comes in various brands, each with its own set of benefits, but their structures are all the same.
The laser generator, torch head, control motherboard, operating system, circuit components, sheet metal enclosure, and other components make up laser welding equipment.
A good piece of equipment must choose better components, and equipment made up of good components will be more stable and have higher performance.
Pursuing the low price should start from the components to reduce the cost, and the corresponding price will be lower.
Various companies make laser welding machines, and the level of technology varies. A manufacturer’s technical strength can be seen from the product composition of the equipment, commissioning, and after-sales maintenance.
The corresponding cost will also increase for manufacturers with a certain number of technical personnel. The price of such manufacturers’ equipment will not be too low, and some manufacturers without core technology will promote the market with low prices. The principle of a penny for a pound is very practical here.
Equipment transactions will involve after-sales issues.
Long-term use of a laser welding machine is certain to cause issues.
Production will be delayed for a longer period if there is a problem with the equipment, which is a good test of the manufacturer’s after-sales ability.
The excellent after-sales staff allows customers to better production and increases manufacturers’ cost. This service is less for manufacturers who do not provide after-sales service, and the corresponding price will be lower.
The level of development of the manufacturing industry is one of the factors that reflect the comprehensive strength of a country and reflect the national economic growth.
People’s consumption concepts have changed as the economy has grown. Product quality and functionality requirements have risen, requiring laser welding equipment manufacturers to constantly improve the manufacturing process, improve quality, and increase production efficiency to meet market demand and user recognition.
Currently, manufacturing companies’ demand for laser welding machine equipment is increasing. The reason for this is that laser technology is used for welding processes. It has the benefits of quick welding speed, a firm and attractive weld seam, no secondary grinding treatment, simple operation, automatic mass production processing, and so on, improving product processing efficiency and lower labor costs for businesses.
Therefore, the market demand for laser welding machine equipment is huge, and there are many laser welding manufacturers in the market.
Different laser welding equipment has varying levels of quality, with prices ranging from tens of thousands to hundreds of thousands of dollars.
Many users do not know how to choose in the face of many laser equipment manufacturers.
Let me briefly introduce some factors you need to refer to when buying laser welding equipment.
1. First, determine whether their welding criteria, such as welding thickness and penetration requirements, are compatible with the manufacturer’s equipment.
2. The laser welding machine’s quality must be considered.
After all, tens of thousands of dollars for a piece of machinery is not chump change. It is best to visit the site for sample welding before purchase to understand whether the functional requirements of the equipment are appropriate.
3. big brand manufacturers and small brand manufacturers of equipment selection
Some clients feel that the quality of laser welding machines made by large brands must be superior to that of small businesses.
There is no certain standard.
Users buy equipment to create value and gain profit.
The price of equipment from large companies is much higher, which leads to increased costs. The equipment of non-large brand companies is generally available at a significant discount in price. The quality is not necessarily worse than that of the brand companies, which is worth considering and the cost effectiveness.
The quality of the after-sales service of laser welding machine manufacturers is a great concern for many consumers.
After purchasing welding equipment, you also need the manufacturer’s technical staff to the site for debugging, layout, and choosing the configuration according to the actual production situation.
If subsequent equipment or parts need to be replaced, the manufacturer should be contacted promptly for processing.
Because of the rapid advancement of laser technology, there are many different brands of laser welding equipment on the market, and the quality of the items varies. Buyers generally do not know where to start when purchasing laser welding equipment.
What factors should we consider when selecting laser welding equipment?
When it comes to laser welding machine equipment, we have a variety of solutions.
When choosing laser welding equipment, we must first determine whether our products are suitable for welding with laser welding machine equipment.
In the past, we assessed the circumstances of over 200 consumers.
Laser welding is not suitable for two categories of products in particular.
The most suitable workpieces for laser welding are thin sheet workpieces with a good consistency (typically no more than 3mm thick) and a weld seam width of no more than 10% of the sheet thickness. A double-swing welding joint is required for welds that are slightly over the thickness, but the swing point can cause laser energy dispersion and affect cutting efficiency.
We do not recommend our customers use laser welding for workpieces with excessively large weld seams. Similarly, the high cost of the equipment and the correction process make laser welding of thick plates difficult. Customers are not advised to use it at this time.
For example, if the welding depth of the product is between 2.5mm-3mm and the laser welding machine is more than 3mm, it is not suitable.
Currently, most manufacturers of laser welding equipment will offer free prototyping services. Before purchasing, make sure to let the other party take a sample to see the effect, and then determine whether the use of laser welding equipment can meet your requirements.
Manual welding or automatic welding?
Precision welding includes two aspects: good welding of precision products and high requirements for the weld seam of welded products. Laser welding falls under this category.
If the weld seam contains more than 15 wires, the wire must be filled, and only manual welding machines can be used.
On the contrary, it can be automated if the weld seam is less than 15 wires. Gapless is best because laser welding is achieved by self-melting the sample.
If there are many types of workpieces, small quantities per batch, making tooling is too troublesome, or if the workpieces are difficult to position and the welding position is hard to reach, spot welding is most common, then handheld laser welding can be considered.
Handheld laser welders have become very popular in the past two years, but the fact is that they are useless and cannot be used for the right purpose. Unscrupulous and unscrupulous dealers have defrauded the majority of customers.
Because manual laser welding is difficult to regulate the position of the spot and focal point, even a small deviation can affect the welding outcome. This method’s welding consistency is poor, and manual operators find it difficult to weld continuously for long periods.
Furthermore, the risk of hand laser welding is substantial, and the dangers posed by accidents are significant.
Customers must be careful when choosing handheld laser welding and not be fooled by welding videos.
After that, let’s talk about the automatic laser welding method.
Suppose the customer has a complex welding track with many curved tracks, specially shaped tracks, or several sides that must be welded simultaneously. In that case, we recommend a handheld laser welding machine.
It not only has a high degree of flexibility, but it also works with specific tooling and a linkage table that can be clamped consecutively and welded fully autonomously, allowing for multi-machine synergistic welding.
If the customer has a simple workpiece with long and straight welding seams or intersecting lines of standard pipe fittings, we recommend using a modular laser welding machine.
The laser generator is the core component of the laser equipment. Generally speaking, the higher the power, the higher the price.
This is because, in terms of hardware configuration, the higher the power, the higher the laser bar and cooling system requirements.
In general, the greater the welding depth and thickness, the higher the power of the laser welder.
If the welding depth you require is 0.5mm, a 200W laser welder will do the job.
Note that for penetration welding and spot welding, 200W is sufficient.
It is best to use a slightly higher laser power for continuous welding, as a 200W laser welder can weld up to 0.8mm deep.
Because the welding depth for continuous welding is around 0.5mm, a 250W or 300W laser welder is recommended.
The deeper the welding depth, the higher the power of the corresponding laser welder.
The hardware configuration of laser welding equipment covers many fields and differs for different uses of laser welding machine equipment.
For example, welding sheet metal boxes, fillet and lap welding of stainless steel and carbon steel, fiber laser welding equipment, and other hardware configurations vary in price.
For instance, penetration depth, width, tensile force or gas tightness requirements, welding length, weld seam shape, and so on. These determine our choice of laser power, core diameter, welding joint ratio, robot spacing, floor rail length, welding process, etc.
Some consumers prefer international brands because they are more expensive.
The cost of laser welding machine equipment made in the United States is lower. Now our domestic technology is constantly being updated. Domestic laser technology has reached the international level. It will be more secure and handy if there are any after-sales issues.
We can choose according to our cost, budget, and purpose.
After reading the four important elements listed above, I’m confident you’ll be able to select a laser welding machine that meets your specific requirements.
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