Laser welding is the preferred welding method in industries like aerospace, where even the slightest imperfection can lead to failure. Laser welding can join a wide range of materials — such as metals, plastics, and even ceramics.
Laser welding provides precision that traditional welding methods cannot. This type of welding focuses a beam of light that can sometimes be thinner than a human hair, creating incredibly strong and clean welds without the risk of material warping or distortion.
Key Takeaways
- Laser Welding Works on a Variety of Materials – It is highly effective for metals like stainless steel, aluminum, titanium, copper, carbon steel, and nickel alloys, as well as non-metals like plastics, ceramics, and glass.
- Precision and Strength – Laser welding creates strong, clean welds with minimal heat distortion, making it ideal for high-strength materials and delicate applications.
- Industry Applications – Laser welding is widely used in aerospace, medical devices, automotive, electronics, and industrial manufacturing, where precision and reliability are critical.
- Challenges & Solutions – Some materials, like aluminum and copper, are reflective and require special techniques (e.g., pulsed lasers or high-power beams) to ensure strong welds.
- Safety First – Proper protective gear, ventilation, and enclosed welding setups are essential to prevent injuries from high-powered laser beams and fumes.
- Automation-Friendly – Laser welding integrates well with robotics and CNC systems, making it a go-to choice for automated, high-precision manufacturing.
Table of Contents
What is Laser Welding?
Laser welding is right for projects that need to join high-strength materials, like metals and plastics, with precision. The laser beam focuses energy on a specific spot of the material, causing it to heat up and melt. The material fuses together as it melts, forming a strong bond. The laser is concentrated, so heat is localized to a very small volume, and as a result, the surrounding area is less likely to be damaged during welding.
Laser welding is particularly advantageous for projects requiring:
- High-strength joints in metals and plastics
- Minimal thermal impact
- Precision and automation-friendly welding techniques
Metals That Can Be Welded with a Fiber Laser
Laser welding is especially popular in metal fabrication because of its ability to handle different types of metals, from the toughest alloys to more lightweight materials. Here’s some of the metals that laser welding can handle:
1. Stainless Steel
This material is valued for its strength and corrosion resistance, which makes it a key choice for food processing facilities, medical devices, and chemical transport equipment. Laser welding stainless steel is seamless because the laser heats the material evenly and precisely — creating strong, clean welds with minimal heat distortion. It’s especially useful for welding medical devices because the depth of penetration can be carefully controlled.
2. Aluminum
Aluminum is light and strong, which is why it’s used so much in the automotive and aerospace industries. Welding aluminum is challenging because it’s highly reflective. This reflection prevents enough heat from reaching the weld area, making it hard to create strong bonds. To overcome this, fiber laser welders can use pulsed mode. A higher-power pulse initiates the penetration, then the power tapers off to a lower level. That way the metal gets penetrated, but the average heat input remains low and the metal does not get distorted.
3. Titanium
Titanium is used in industries where strength, low weight, and corrosion resistance are imperative. Titanium is most commonly seen in aerospace, medical implants, and high-performance automotive parts. Laser welding works well with titanium because it directs heat to a small, focused area, which is important for this sensitive material. It also reduces the risk of contamination, ensuring precision in delicate applications.
4. Copper
Laser welding copper is used mostly in the electronics industry. Copper has excellent electrical conductivity but is also highly thermally conductive, meaning it can dissipate heat quickly, which is quite a challenge for traditional welding techniques. When it comes to laser welding, copper is very reflective, so it takes a lot more laser power to penetrate copper. For example, penetrating 2mm thick (16Ga) mild steel takes roughly 530W, but penetrating the same thickness on copper takes a whopping 1300W. However, with enough power, laser welding is still the optimal welding process for copper as it significantly reduces the HAZ (heat affected zone).
5. Carbon Steel
Whether it’s used in construction, automotive, or heavy machinery, carbon steel is a go-to for its strength and cost-effectiveness. Laser welding carbon steel produces precise, high-quality welds with minimal heat distortion, which is especially helpful when working with thinner gauges of material. However, laser welding is great for thicker joints as well because it eliminates arc blow. Commonly sold fiber lasers can easily penetrate up to 6mm (4Ga) mild steel.
6. Nickel Alloys
Nickel alloys, which are known for their high heat and corrosion resistance, are widely used in industries like chemical processing, aerospace, and power generation. These alloys can be a challenge to weld using traditional methods, but laser welding gets the job done efficiently. The ability to control the laser’s power and focus makes it ideal for welding nickel alloys without compromising their structural integrity.
Metal Reflectivity and Laser Power
As we noted earlier, the higher the metal reflectivity is, the higher power we need to use to penetrate the same thickness. Let’s look at a metal reflectivity table kindly provided by the University of Columbia:
| Materials | k | n | R |
| Al | 8.50 | 1.75 | 0.91 |
| Cu | 6.93 | 0.15 | 0.99 |
| Fe | 4.44 | 3.81 | 0.64 |
| Mo | 3.55 | 3.83 | 0.57 |
| Ni | 5.26 | 2.62 | 0.74 |
| Pb | 5.40 | 1.41 | 0.84 |
| Ti | 4.0 | 3.8 | 0.63 |
| W | 3.52 | 3.04 | 0.58 |
| Zn | 3.48 | 2.88 | 0.58 |
| Sn | 1.60 | 4.70 | 0.46 |
| Glass | 0 | 1.5 | 0.04 |
R is the reflectivity index. We can see that welding copper and aluminum requires much more power than steels that have more iron and zinc in them.
Non-Metallic Materials That Can Be Laser Welded
While laser welding is most commonly associated with metals, advances in technology have made it possible to weld a variety of non-metallic materials as well. Fiber lasers are optimal for metal welding, but CO2 and Nd:YAG lasers can also be used to join other materials. Here are some of the more interesting options:
1. Plastics
Laser welding is perfect for plastic materials like polycarbonate, polypropylene, and ABS, enabling clean, accurate welds. This technique joins parts seamlessly and firmly while preserving the material’s strength and quality. No mess, no adhesives—just clean, strong welds.
2. Ceramics
While laser welding ceramics is still a niche application, it’s slowly gaining use in industries like electronics and aerospace. Ceramics are notoriously tricky to join using traditional welding methods due to their brittle nature, but lasers can heat specific areas without affecting the overall material. This results in strong, reliable bonds in delicate and high-performance parts — like sensors and electronic components.
3. Glass
You might think glass is impossible to weld with lasers, but that’s not the case anymore. Laser technology is now being used to create strong, high-quality joints in glass, especially in fields like telecommunications and medical devices. By directing the laser precisely at the bonding area, it’s possible to fuse glass pieces together smoothly, without causing cracks or defects.
Laser Welding Safety Precautions
Laser welding has some great benefits, but it’s not without its risks. The powerful lasers involved can be hazardous if safety guidelines aren’t strictly followed. Here are a few key precautions to keep in mind:
1. Protect Your Eyes
Laser radiation is intense, and exposure to the beam can cause serious eye damage. Always wear laser safety goggles specifically designed to filter out the harmful wavelengths of light emitted by the laser. It’s not just a suggestion—it’s a must for anyone working with laser welding equipment. Most importantly, remember that fiber laser light used for welding is invisible to the human eye because its wavelength (1070nm) is outside of the visible spectrum. Never let anybody be present in the direction of the reflected light. If you don’t see it, does not mean it’s not there!
2. Use Fire-Resistant Gear
Welding creates heat, and laser welding is no exception. Depending on the material being welded, molten metal or plastic can splash around. Fire-resistant gloves, clothing, and face shields should be part of your standard gear. This will protect you from burns and other heat-related injuries.
3. Ventilation is Key
Laser welding can release fumes, especially when working with metals like aluminum and copper. These fumes can be toxic, so proper ventilation is essential. A high-efficiency fume extraction system will help keep the air clean and safe to breathe. Always ensure your workspace is well-ventilated before starting a job.
4. Proper Training is Essential
Laser welding equipment is complex and powerful. That’s why proper training is essential. Only trained operators should be handling lasers, and they should be fully familiar with the equipment, safety protocols, and emergency procedures.
5. Routine Maintenance
To ensure your equipment stays safe and functional, regular maintenance is a must. A well-maintained laser welding machine operates more efficiently and safely, reducing the risk of accidents and extending the life of your equipment.
6. Proper Safety Setup
All fiber lasers used for welding are Class 4 lasers. This means that the welding process must happen inside of an enclosure to avoid injuries to other people in the shop. Part of the laser beam always gets reflected at the incident angle. The enclosure must cover all four walls around the welding zone and must have a roof if the ceiling of your shop has reflective surfaces on HVAC ducts or water supply pipes.
FAQ
Can all metals be welded with a laser?
Most metals can be welded with a laser, including stainless steel, aluminum, titanium, copper, and carbon steel. Some metals, like high-reflectivity materials (like copper), require pulse welding techniques for good penetration.
Is laser welding suitable for plastic materials?
Laser welding is super effective for joining plastic parts, especially in industries like automotive and electronics. It works well with materials like polycarbonate and acrylonitrile butadiene styrene (ABS).
Can laser welding be used on ceramics?
Laser welding is increasingly used for ceramics, especially in electronics and aerospace. The laser can precisely heat specific areas of the ceramic, creating strong bonds without affecting the material’s brittle nature.
What safety precautions should I follow when laser welding?
Always wear laser safety goggles, fire-resistant clothing, and gloves to protect against heat and radiation when laser welding. You need to have proper ventilation and follow training guidelines to avoid accidents, and also ensure your environment is enclosed.
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.