Laser welding is a cutting-edge technique for joining metals and thermoplastics that has revolutionized the manufacturing and engineering industries. Unlike conventional welding techniques, laser welding offers exceptional speeds and can effectively weld many different materials, from steel to acrylic.
Understanding the Role of Lasers in Welding
Laser welding uses a highly concentrated beam to rapidly heat a small area to melt the material and form a molten pool. As the pool cools, it fuses the materials to create a strong bond.
Laser welding is a more effective choice than traditional options like spot and arc welding for several reasons:
Arc welding is a joining process that uses electricity to create a temperature arc to melt and fuse metal. Unlike arc welding, laser welding uses a focused laser beam to produce durable and aesthetically pleasing welds.
Spot welding is an older method that joins metal sheets through pressure and current without filler materials. Laser welding is able to complete the same outcomes as spot welding more efficiently and provides the option for automation to streamline your overall operations.
There are also multiple laser welding techniques available, depending on your material and the desired result. These include the following.
Conduction Welding
Conduction welding uses the process of heat conduction to melt materials. As the laser beam hits the surface, it creates an even distribution of heat and causes the material to melt without penetrating the workpiece, making it ideal for materials with low melting points. Conduction welding is a great choice for industries sensitive to heat input and control in welding, such as jewelry, electronics and medical devices.
Keyhole Welding
Keyhole welding uses a high-energy laser to heat the material past the fusion point, causing it to melt and then vaporize. As the material vaporizes, it leaves behind a narrow cavity called the keyhole. The molten material then flows into it for a solid bond free from imperfections.
Keyhole welding is ideal for thicker materials with higher melting points, making it a great choice for applications like aerospace and automotive manufacturing.
Key Benefits of Laser Welding
Laser welding is the latest in welding technology advancements and has become popular in industries requiring speed, precision and quality.
Some of the many benefits laser welding provides are:
Material compatibility: Welds dissimilar materials like steel and aluminum, and some thermoplastics. The keyhole welding technique also allows for the penetration of thicker materials with minimal heat input.
Energy efficiency: Delivers heat directly to the weld seam to minimize the heat-affected zone and reduce thermal damage or distortion.
Cost reduction: Offers faster processing, higher production capacity and eliminates post-processing for greater time and money savings.
Automation integration: Seamlessly integrates into your existing automated production line to reduce the need for manual intervention and guarantee quality consistency.
Weld quality assurance: Provides precise alignment and cleaner seams to enable the welding of small or delicate parts without the risk of damage or distortion.
Industry Applications of Laser Welding
The precision, efficiency and versatility of laser welding make it a valuable tool across many different industries, including:
Aerospace: Laser welding can be used to create strong weld joints in turbine components and is beneficial for applications such as in-space manufacturing and repair.
Automotive: Manufacturers can form a strong bond with many automotive materials and metals through welding with minimal distortions. Some applications include tailored blanks, tubes and hang-on parts like doors and side panels.
Medical devices: Laser welding is beneficial in creating sensors, medical implants and other delicate devices that require strong bonds without affecting the components surrounding the weld site.
Jewelry: This type of welding is compatible with precious metals, like gold and silver, and can aid in creating intricate pieces or repairing and resizing jewelry.
Frequently Asked Questions About Laser Welding
Explore these commonly asked questions regarding laser welding.
How Long Do Laser Welders Last?
The average lifespan of laser welding equipment depends on several factors, including:
Machine quality
Frequency of use
Work materials
Maintenance
Operating environment
Power output
Laser type
What Types of Lasers Are Used in Laser Welding?
Two of the most common types of lasers used in laser welding machines include the following:
Gas lasers use gases such as carbon dioxide and nitrogen. They typically have higher power outputs for greater efficiency. These lasers have higher continuous wave and power outputs to make them ideal for thicker materials and welding projects that require an emphasis on speed.
Solid-state lasers use solid materials like crystals. They can also achieve high power outputs, and their precise beam quality makes them a great choice for smaller projects across industries such as automotive, aerospace and medical.
How Do I Choose the Right Laser Welding Machine for My Business?
The right laser welding machine for your business will depend on the following factors:
Type: Laser machines are available in automatic 3D laser and manual handheld options. 3D setups are ideal for bulk production, while handheld lasers are better for small and medium-scale demand.
Power: A machine with a higher power output allows for faster welding and can handle thicker materials, but it also impacts your business’s energy consumption. A machine with lower power outputs may work for smaller-scale production needs but may sacrifice speed.
Laser configuration: The type of laser you choose significantly impacts the machine’s overall performance, and you will want to choose an option based on wavelength, material application and heat input.
What Do Shielding Gas and Filler Materials Do in Laser Welding?
Shielding gas is a common material in laser welding. It protects the molten weld pool from atmospheric contaminants like oxygen and nitrogen. Inert gases like argon and helium are sometimes used to create a protective atmosphere, which prevents the formation of defects like voids and ensures the overall quality of the final weld joint.
Filler materials, such as powders or wires made of similar alloys, are not always a requirement in laser welding. They can be a solution to bridge gaps or enhance weld strength. Adding filler material can make it easier to adjust the chemical composition of a weld to help you achieve the desired properties.
Partner With Meritus Gas Partners for Laser Welding Solutions
Precise laser welding starts with Meritus Gas Partners. We partner with many leading distributors and offer a wide selection of industrial gases and welding equipment. We make finding the right option to meet your business’s specific welding requirements easy.
Our skilled team has decades of experience in the welding industry, and we will use our knowledge to provide expert support.
