Laser Welding

Laser welding uses a high-energy-density laser beam as a heat source to locally heat metal materials to a molten or partially molten state, thereby achieving material connection.

Advantages of Laser Welding

1. Concentrated energy, small heat-affected zone, and minimal deformation.

Laser welding uses a focused laser beam, concentrating high energy into a small focal point to melt the metal. This results in a narrow weld penetration and a smaller heat-affected zone, minimizing thermal deformation. Furthermore, the laser's frequent on-and-off "pulsing" process repeats melting and solidification several to dozens of times per second, further minimizing deformation.

2. Ensures sufficient weld strength

Laser welding has a thin weld bead, which can sometimes lead to concerns about insufficient strength. However, due to its deep weld penetration, it possesses sufficient internal strength compared to its appearance. Since laser welding involves a smaller amount of alloy that temporarily melts and solidifies, fractures are avoided. Strength tests conducted at industrial testing sites have confirmed that laser welding has strength exceeding that of TIG welding.

3. High weld quality and high welding speed.

4.High automation,making it suitable for precision manufacturing and large-scale production.

Disadvantages of Laser Welding

1.Poor Gap Management

Laser welding focuses laser energy on a very small spot, approximately 0.1 to 0.6 mm in diameter, to melt the metal. This property makes it difficult to weld if there are gaps. For a machine with a spot diameter of 0.1 mm, a gap as small as 0.1 mm will cause the laser to pass through it, preventing welding. Therefore, measures such as improving bending process accuracy and installing jigs are necessary.

2.Inadequate Build-Up Welding

Laser welding excels at welding base metals, but not at build-up welding. Besides the possibility that the laser energy may not fully reach the base metal at the point where the welding rod melts, it is also difficult to precisely align the weld point, rod, and focal point, potentially failing to ensure sufficient strength. If build-up welding is specified in the drawing, it is important to consider whether laser welding is appropriate. Conversely, if laser welding is desired for strength and aesthetics, it is best not to specify build-up welding.

3.Higher investment costs compared to traditional processing methods.

4. Limited material thickness.

Laser Welding Processes

1.Continuous Welding: Produces a continuous, smooth weld seam, suitable for long, straight welds;

2.Pulse Welding: Uses laser pulses to control heat input, suitable for micro-welding and heat-sensitive parts;

3.Spot Welding: Single or multi-point welding, an alternative to resistance spot welding;

4.Hybrid Welding: Combines laser welding with MIG/TIG or arc welding, achieving both deep penetration and metal deposition.