Laser welding is not as common as MIG, TIG, and arc welding. That’s primarily because it required significant investment until recently.
However, fiber laser technology made significant strides around 2006, significantly lowering costs. Over the past 18 years, additional developments have lowered production costs and laser welding machine ownership costs.
At this point, laser welding is practical for all kinds of manufacturers, not just those with large quantity production lines. Even handheld devices are becoming more popular.
Since laser beam welding is so widely available, now is a good time to investigate this tried-and-true method that offers accuracy, speed, and affordability.
How it works
Laser welding uses a beam to join metals or thermoplastics. Since it is such a concentrated heat source, laser welding may be done at high welding speeds of meters per minute in thin materials. It can also create narrow, deep welds between square-edged pieces in thicker materials.
Consider laser welding to be similar to the sun and a magnifying glass. If enough energy is directed at its surface, metal can be melted and, in certain situations, even vaporized.
The extremely high power density produces a concentrated heat source of millions of watts per centimeter. However, more laser power is required for deep penetration or rapid laser welding speeds. Laser power is the primary driver of machine cost.
Laser welding is suitable for any substance that can melt and resolidify. It can weld various metals like copper, stainless steel, and aluminum. It is also used on specific kinds of thermoplastics, glasses, and composites.
Types of laser welding
Laser welding solutions have two basic operation modes. These are keyhole welding and conduction-restricted welding. The power density across the beam striking the workpiece determines the form of interaction between the laser beam and the material being welded.
Conduction welding
Conduction welding is a gentle method in which the laser beam gradually melts the metal. In this kind of welding, the temperature of the metal rises above its fusion point and becomes liquid, but it never becomes gaseous. The metal transfers heat in a similar way in all directions.
Conduction welding produces better outcomes with little to no spatter and low fumes. However, it is slower.
Keyhole welding
Keyhole welding is a quick, yet forceful, method that penetrates deeper into the material by melting and vaporizing the metal. In certain places, the metal reaches both its fusion and vaporization temperatures.
This can lead to spatter because a portion of the melting pool is in the gaseous condition. The majority of the heat transfer in the metal occurs perpendicular to the laser beam.
Keyhole welding is quicker and better suited for high-volume production lines. However, it can result in porosity and a larger heat-affected zone (HAZ).
Applications of laser welding
Several industries employ laser welding for particular purposes, such as:
- Medical Industry: This industry makes substantial use of it, and common applications include implanted devices, surgical tools, and medical equipment.
- Automotive Industry: Used to connect parts such as gasoline tanks, exhaust systems, body panels, and even electric car batteries.
- Electronics Manufacturing: Used to seal electronic housings, weld microelectronic components, and make delicate connections on circuit boards.
- Aerospace Industry: Used to manufacture engine components, sensors, fuselage sections, turbine blades, and similar assemblies.
- Semiconductor processing: This is one of the fields with the fastest rate of growth. Here, laser welding is used to construct semiconductor packages, sensors inside microchip printing machines, and magnetic assemblies needed in different phases of semiconductor processing.
Micro Weld engineers employ laser welding in situations that call for accuracy, rapidity, and adaptability.
To Sum Up
Laser welding is a technique for joining metals or thermoplastics using a beam. It offers incredible possibilities thanks to its accuracy, speed, and high degree of control. If you are unfamiliar with this technology, discussing your application with a specialist is advisable. They can help you determine whether it is a good fit for you.
