Most of us know what welding is, but what about laser welding? I was stunned when I first learned about it.
As technology advances humans find ways to make work easier. Thus, the invention of laser welding — an extremely advanced and efficient technique used across a multitude of industries for joining materials.
From aerospace and automotive to medical devices and electronics, laser welding is recognized for its precision, speed, and minimal heat distortion.
Key Takeaways
- High Precision and Speed: Laser welding allows for high accuracy and speed. It is ideal for applications requiring fine detail and dimensional accuracy.
- Minimal Heat-Affected Zone (HAZ): The concentrated heat input results in a smaller HAZ. This results in significantly lower heat distortion than from other welding methods like MIG and TIG.
- Versatility: Laser welding is capable of welding a wide range of materials, including carbon steels, stainless steel, aluminum, titanium, and various polymers.
- Automation Compatibility: The process integrates well with robotic systems because it allows for precise control without a plethora of additional sensors and feedback loops.
Table of Contents
What is Laser Welding?
Laser welding suits projects that require the joining of high-strength materials such as metals and plastics, as well as precision, since it employs a focused beam of light. The laser beam focuses energy on a specific spot of the material, causing it to heat up and melt. As it cools, the material fuses together, forming a strong bond. Because the laser is concentrated, heat is localized to a very small volume. As a result, the surrounding area is less likely to be damaged during welding. This is one reason why laser welding is regularly used for applications requiring high accuracy and durability, such as in high-performance or delicate parts.
How Does Laser Welding Work?
Laser welding is the use of a laser beam directed to a focal point of two metals (the workpieces). The energy of the laser is absorbed by the material and it heats up until it melts.As the material melts, it forms a molten pool. The molten material cools and solidifies, creating a strong joint between the workpieces. Laser welding can be done using either continuous or pulsed lasers, depending on the specific requirements of the application.
The welding process is usually automated, allowing for precise control of the welding parameters, such as the laser power, speed, and spot size. This can be done in different positions (flat, horizontal, vertical) and the laser focus and energy can be set for various materials and thicknesses.
Laser Welding: Basic Steps
Here’s an overview of the typical steps in the laser welding process:
- Preparation: First, clean the pieces to be welded, then properly align and fix them in place.
- Laser Beam Application: Next, direct the laser beam at the joint, where it will melt the material.
- Formation of the Weld: The molten material will then cool and solidify, which forms a bond between the materials.
- Cooling and Inspection: Once the weld has melted, it’s given time to cool, and then its quality is checked to make sure it meets the required standards.
Types of Laser Welding
There are a few different laser welding methods, each designed for specific materials and applications. The main types include:
1. Continuous Wave (CW) Laser Welding
Image credits to: ebindustries.com
The continuous wave laser welding method uses a constant laser beam to melt and join materials, which is optimal for creating deep, narrow welds in materials that are fairly thin. It’s helpful to think of it like using a precise, concentrated beam of light that acts as a high-tech torch. The steady beam makes it so that heat is evenly spread across the material during the welding process, which results in clean, durable joints. CW laser welding is typically used in industries where high specificity and repeatability are essential, like in electronics and automotive manufacturing.
2. Pulsed Laser Welding
Image credits to: amadaweldtech.com
Pulsed laser welding involves short bursts or pulses of laser energy, rather than a continuous beam. This method allows for better control over heat input, which is excellent for welding heat-sensitive materials. Pulsed laser welding is often used in applications that need minimal thermal distortion, such as in the medical and aerospace industries. The quick pulses also help reduce the risk of overheating and material degradation, allowing for more detailed and delicate welding.
3. Keyhole Laser Welding
Image credits to: www.ionix.fi
Keyhole laser welding is a technique where the laser’s energy vaporizes the material at the welding point, creating a tiny “keyhole” in the metal. This allows for deeper welds, which is best for thicker materials or situations where deep penetration with minimal distortion is needed. It’s generally used in fields that demand strong, durable joints, like automotive and heavy equipment manufacturing.
4. Hybrid Laser Welding
Image credits to: ahssinsights.org
Hybrid laser welding combines laser welding with another welding process, such as arc welding. The hybrid technique combines the speed and consistency of the laser with the robustness of the arc process, making it ideal for welding thicker materials or materials with complex geometries. This method is particularly favored in automotive manufacturing and heavy industries, where high-speed, high-quality welds are required.
What Types of Lasers Can Weld?
Laser Type | Characteristics | Common Applications |
CO2 Lasers | Known for their power and flexibility | Welding materials like steel, stainless steel, and aluminum |
Fiber Lasers | High efficiency and excellent beam quality | Welding materials such as copper, aluminum, and high-strength alloys |
Diode Lasers | Small, energy-efficient, and precise | Detailed welds in disciplines like medical device manufacturing |
YAG Lasers | Designed for deep penetration welding | Often used in aerospace and automotive sectors |
What Are the Advantages of Laser Welding?
Laser welding is compatible with a broad range of materials, specifically metals and alloys. Some of the most commonly welded materials include:
- Steel (including carbon steel, stainless steel, and tool steel)
- Aluminum and its alloys
- Titanium and titanium alloys
- Copper and copper alloys
- Nickel and nickel alloys
- Gold and other precious metals
- Plastics (in some cases, especially in the automotive and medical industries)
One of the most critical advantages of laser welding is that it completely eliminates arc blow—a common obstacle in traditional arc welding caused by magnetic fields. These fields can deflect the welding arc, make it unstable, and force it to wander away from the intended weld path. By removing this issue, laser welding ensures precise, high-quality welds. This, combined with its ability to work with a variety of materials, makes laser welding invaluable in industries like high-end electronics and aerospace.
Examples of Laser Welding Machines
Laser welding machines are available in various configurations to meet the specific needs of different domains. Some examples include:
1. Battery Welding Machines (Remote Welding)
Battery welding machines are built to weld the delicate parts of batteries, like those found in electric vehicles (EVs) and mobile devices. They use precise lasers to join terminals, electrodes, and battery packs while making sure not to damage any sensitive components.
2. Handheld Laser Welding Systems
Handheld laser welding machines offer mobility and flexibility, making it easier for operators to weld in tight or hard-to-reach spaces. They’re often used for repairs, maintenance, and small-scale production.
3. Robot Welding Machines (Remote Welding)
Robot welding systems use robotic arms paired with laser welding heads to automate the entire welding process. These systems are the right option for high-volume production and are widely used in the automotive industry to weld car frames and other structural components
4. Robot Welding of Car Frames
In the automotive sector, robot welding systems are used to weld car frames with meticulousness. By using laser welding, these robots create strong, lightweight joints that improve both the vehicle’s strength and overall performance.
What Are the Applications of Laser Welding?
Some of the most prominent sectors that rely on laser welding technology include:
1. Automotive Industry
In the automotive industry, laser welding is popularly used to manufacture car bodies, exhaust systems, engine parts, and battery assemblies. Its precision and speed make it best for creating the complex components and joints found in modern vehicles. Laser welding is also often used in the assembly of electric vehicles (EVs), where its ability to create lightweight, detailed welds is vital.
2. Aerospace Industry
The aerospace industry demands high-strength, lightweight materials, and laser welding is the most suitable and efficient method for joining components made of aluminum, titanium, and other alloys. Laser welding is used for assembling airframes, engine parts, fuel systems, and other critical components where structural integrity and consistency are essential.
3. Medical Devices
Laser welding is widely used in the medical device market to create precision parts such as surgical instruments, implants, and medical equipment. The ability to weld small, delicate components without causing thermal damage is especially valuable in this sector. Additionally, the clean, sterile welds produced by laser welding are essential for medical applications.
4. Electronics Manufacturing
Laser welding is frequently used in electronics manufacturing to join delicate parts like connectors, circuit boards, and other small components. Thanks to its precision, laser welding can fuse these tiny parts without damaging sensitive electronics or causing overheating.
5. Energy Sector
Laser welding is employed in the energy sector for the construction and maintenance of power plants, oil rigs, and renewable energy systems. It’s most useful for welding thick materials and creating strong, dependable joints that can handle high pressure and extreme temperatures.
6. Jewelry Manufacturing
Laser welding is becoming more popular in the jewelry business for creating detailed designs, repairing pieces, and joining precious metals. Its neatness and low heat output make it perfect for working with delicate, valuable materials.
FAQ
What is laser welding?
Laser welding is a process that uses a focused laser beam to melt the material at a specific point, creating a strong bond as it cools. The localized heat input and the ability to precisely control the beam make laser welding perfect for industries with strict weld quality requirements.
What is laser welding used for?
Laser welding is used to join metals and plastics with precision. It’s commonly applied in industries like automotive, aerospace, electronics, and medical devices, where strong, durable welds are needed for small or delicate parts. It’s superior for thin parts because it creates minimal distortion.
Is Laser Welding Safe?
Yes, laser welding is safe when the right safety measures are in place. It’s important to wear protective gear like laser safety glasses and shields since the lasers can be harmful to your eyes and skin. Operators also need proper training to use the equipment safely in a controlled setting.
What Industries is Laser Welding Used In?
Laser welding is utilized across industries like aerospace, automotive, electronics, and medical devices due to its ability to provide extremely precise, strong, and clean welds. It’s perfect for delicate and complex applications, from fine electronics to critical aerospace components.
Emma Ascott
Emma Ascott is a journalist specializing in technological subjects, with a bachelor’s in Journalism and Mass Communication from Arizona State University. She has worked for Arizona PBS, nuclear fusion company TAE Technologies, and Future of Work publication Allwork.Space. Emma is the PR lead at MavWeld.