The Advantages of Laser Welding over Traditional ...

Laser Welding vs. Traditional Welding Methods

TIG and MIG welding have long been recognized as good choices for welding small components because of their excellent finish. However, such welding requires skill and dexterity, and despite their controllability, suffer from several disadvantages. Laser welding is an excellent substitute that frequently outperforms arc welding processes, and its tightly focused beam limits heating effects. Laser welding is capable of welding tasks beyond the capability of traditional welding methods.

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Traditional Welding Methods

TIG and MIG processes use a shielding gas to create an inert atmosphere around the welding head. With TIG, the arc is created by a tungsten electrode, and a hand held filler material used, whereas with MIG welding the electrode is the filler wire. These welders can be adjusted to permit welding of delicate components and the final weld quality is high. Another frequently used method is spot-welding which works by clamping parts between a pair of electrodes and passing an electric current. All arc and spot-welding processes transfer a significant amount of heat to the work piece, affecting the metallurgical structure around the weld.

Laser Welding

The heat required for welding is supplied by a tightly focused light beam with a diameter as small as two-thousandths of an inch. Welding is conducted by firing a series of short pulses that melt the metal to create a high-quality weld. Depending upon the particular welding task, filler material may be required as with TIG welding. Because the laser beam is tightly focused, heat input is minimized and parts can be handled almost immediately.

Laser Welding Advantages

Precise control of the laser beam offers users several benefits over TIG, MIG and spot-welding:

• Weld strength: The laser weld is narrow with an excellent depth-to-width ratio and higher strength.
• Heat affected zone: The heat affected zone is limited, and due to rapid cooling, the surrounding material is not annealed.
• Metals: Lasers successfully weld carbon steel, high strength steel, stainless steel, titanium, aluminum, and precious metals as well as dissimilar materials.
• Precision work: The small, tightly controlled laser beam permits accurate micro-welding of miniature components.
• Deformation: Parts have minimul deformity or shrink.
• No contact: No physical contact between the material and laser head.
• One sided welding: Laser welding can replace spot welding requiring access from one side only.
• Scrap: Laser welding is controllable and generates low volumes of scrap.

Applications

The unique properties of laser welding give it a significant advantage over other forms of welding that can be exploited in several ways:

• Precision parts: Lasers are excellent for welding fine and delicate metal components and generating minimal internal stresses due to the minimal heat input.
• Medical devices: Non-contact welding and no welding splatter ensures hygiene when welding medical devices.
• Solenoids and machined items: Lasers are ideal for joining machined components such as solenoids, and create minimal distortion due to the low heat input.
• Aesthetics: Laser welding finishes are excellent.
• Limited access: The non-contact laser beam permits welding in otherwise inaccessible areas.
• Jewelry welding and high value items: The precise controllability and negligible heating effects make it a good choice for welding high value, high precision parts including precious metals. 

Improve Productivity with Laser Welding

Laser welding machine is a new type of welding method, which has many advantages such as low bonding strength and wide heat-affected zone. In the current metal processing market, laser welding has been widely used and has been used in various industries, such as : Metal thermos cups, mobile industry, medical industry and other industries.

Advantages of handheld laser welding machine:

The use of laser beams with extremely high energy density to fuse materials is currently the most advanced welding method in the processing field. Compared with traditional welding technology, laser welding technology is non-contact welding. The operation process does not require pressure, and it has fast welding speed, It has the advantages of high strength, large depth, small deformation, narrow weld seam, small heat-affected zone, small workpiece deformation, less follow-up processing workload, reduced manual output, high flexibility, and safety.

Laser welding technology can weld refractory materials such as high-melting point metals, and can even be used for welding non-metallic materials such as ceramics and plexiglass. It has a good welding effect on special-shaped materials and has great flexibility. For parts that are difficult to access for welding, perform flexible transmission non-contact welding. The laser beam can achieve time and energy splitting, and can process multiple beams at the same time, providing conditions for more precise welding.

Attention points when using laser welding machine:

1. The position of the weldment must be very precise and must be within the focus range of the laser beam;

2. When the weldment needs to use the fixture, it must be ensured that the final position of the weldment needs to be aligned with the welding spot that the laser beam will impact;

3. The maximum weldable thickness is limited, and the workpiece with a penetration thickness far exceeding 19mm needs to consult the manufacturer to provide more professional technical support on the production line.

Application range of laser welding machine:

1. Battery industry

The batteries of mobile phones and most code products are welded by laser.

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2. Bathroom and kitchenware industry

Laser welding is precise and has a good appearance, so it is widely used in laser marking and laser welding of high-end sanitary stainless steel products. For example, handles, faucets, stainless tableware and knives are mostly made of corporate LOGO by laser marking, and the sealing of high-end electric kettles is also completed by laser welding. Welding and butt welding of kitchen utensils and tableware, mold making and repair and modification during mold making and use.

3. Digital products, mobile phones, computer industries

Because laser processing is a precise processing technology, it is more popular in the fields of digital, mobile phones, and computers, such as: laser welding of mobile , MP4, and MP3 shells, spot welding of interface cables, notebook computers, and optical laser welding equipment, and welding of computer case connectors.

4. Construction machinery industry

Purification equipment welding, mechanical and electrical accessories welding, connector bearing repair.

5. Electronics and electrical appliances industry

Since laser processing is a non-contact processing method, there is no mechanical extrusion or mechanical stress, so it is especially in line with the processing requirements of the electronics industry. Such as: welding of transformers, inductors, connectors, terminals, optical fiber connectors, sensors, transformers, switches, mobile batteries, microelectronic components, integrated circuit leads, etc.

6. Jewelry industry

Due to the high precision of laser processing, it is very suitable for precious and small products in the jewelry industry. Because the laser focused beam is extremely fine, it can be enlarged through a microscope to enlarge the small parts of jewelry to achieve precision welding. The linking of jewelry chains and the inlaying of gemstones should be completed with laser spot welding machines, and laser spot welding machines are necessary equipment.

7. Hardware, tools, instrument industry

Assembly welding butt welding of instruments, sensors, kitchen utensils and tableware, mold making and repair and modification during use. Seamless welding of stainless steel tableware, welding of instrument watch core joints.

8. Automobile and electric vehicle industry

Laser processing is non-contact processing, which has no pollution to the product and high speed. It is more suitable for the production process of high-end consumer goods in automobiles, such as welding of automobile dials, welding of valves, welding of piston rings, welding of automobile cylinder head gaskets, and exhaust pipes. , Welding of filter, welding of steam safety gas generator. Laser cutting of parts in automobile trial production and small batch production, electric vehicle battery welding.

9. Energy lighting and building materials industry

Laser processing is widely used in the manufacture of laser solar cells: such as laser scribing and cutting of solar silicon wafers, welding of heat conducting plates for solar water heaters. As an environmentally friendly and efficient processing method, laser processing will be more widely used in the future.

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