Unlike traditional welding methods, laser welding is not a widely practiced technique. However, it offers incredible precision, phenomenal speed, and extraordinary performance.
It opens doors to limitless creativity and possibilities in metalworking. Which is the reason people are leaning towards laser welding.
But before buying a laser welding machine, it is important to understand the nitty-gritty. It is an entirely different technology compared to conventional welding methods.
That’s why we’re here with a comprehensive guide to laser welding. We will explain what laser welding is, how it works, why it is beneficial, and how you can select the best laser welding machine for your needs.
Part 1: What Is Laser Welding?
Laser welding is a contactless welding process that offers incredible strength, precision, and speed while ensuring aesthetic appeal.
The machine contains a laser source that generates a highly focused beam. It is directed towards the joint and concentrated on a tiny area. It transfers heat and instantly increases the temperature of the material.
When the temperature of the metal reaches its melting point, it begins to melt, creating a weld pool. The molecules of both metal pieces fuse together, which is essential for a strong joint.
In some cases, a filler material is also used to fill the gap of the joint and make it stronger. However, it is not mandatory in laser welding. For protecting the weld pool from contaminants, a shielding gas can be used in the process, but it is not always required.
Upon cooling, the melted pool solidifies and creates a strong bond between the metal pieces. The weld quality is exceptional, and it does not require excessive post-processing.
Part 2: Advantages Over Traditional Welding Methods
Laser welding offers distinct advantages that make it superior to traditional welding methods. In various aspects, it is a great option.
Here are some of the advantages it offers.
Incredible Speed
Laser welding is known for its blazing speed. It’s much faster than traditional welding methods. Even a small laser welding machine can offer up to 8X the speed of TIG welding. If the machine can generate immense power, the welding speed will be several meters per minute.
The reason laser welding is fast is because of its focused laser beam. It falls on a tiny area and starts increasing its temperature. The energy density is quite high, which is why it’s capable of melting the area in no time. Because of quick melting, the speed of the welding process is unmatchable.
Exceptional Quality
Even though the speed of laser welding is high, it does not compromise the weld quality. Firstly, it is a non-contact process, which keeps the welding pool cleaner. The risk of contamination is low.
It does not require a filler material or shielding gas. But still, there is no messy slag over the joint. It does not produce spatter and affect the surrounding area. The weld quality is exceptional as it targets a minimal area.
The resultant weld is extremely clean. In most cases, it does not even require post-processing. In other welding methods, you need grinding, hammering, and sanding to get a clean finish.
High Accuracy and Precision
With laser welding, it is possible to achieve high accuracy and precision. The laser spot is extremely small, so it heats a very small area. That’s why laser welding is preferred for welding delicate and tiny objects.
Secondly, laser welding also offers exceptional control to the operator or welder. It is possible to adjust the laser power, speed, frequency, and other parameters to achieve immaculate results.
Minimal HAZ
The most important benefit of laser welding is the minimal heat-affected zone (HAZ). And there are multiple reasons for that.
The laser spot affects a very small area because of its high focus. It targets the area to be welded with incredible precision and transfers the heat.
The surrounding area remains unaffected. The energy density and speed are high, so the temperature of the material increases quickly. It does not allow the heat to transfer to a wider area.
That said, only the area to be welded is under the laser focus. The heat does not travel far and wide and affect the metal properties. That’s why laser welding is an excellent option for welding thin metal sheets. There is minimal risk of warping, distortion, or cracks.
In other welding methods, controlling HAZ is extremely difficult because of a large affected area, high heat, etc. There is a high risk of running into the metal piece or the surrounding area.
Low Running Cost
Laser welding machines are expensive. The upfront cost is a lot more than traditional welding methods. But it is still a viable option for manufacturing and high-volume applications because of the low running cost.
Unlike other welding processes, it does not require expensive filler materials, shielding gases, post-processing equipment, etc. The labor cost and running cost of the machine are quite low. Often, these laser welding machines are automated. Thus, it is a cost-effective option.
Versatility
Laser welding can be used with a wide range of materials. For instance, it can do welding on stainless steel, carbon steel, aluminum, titanium, copper, etc. The best part is that it can even weld dissimilar metals.
It is one of the major reasons it is used in different industries. Its versatility allows it to be used in limitless projects and jobs.
Part 3: Key Applications of Laser Welding
Laser welding can be used for almost any application, depending on its power and other factors. It can even be used as an alternative to traditional welding methods. However, for some applications, laser welding is preferred because it can do what others can’t.
Automotive Industry
Laser welding is an essential welding method in the automotive industry. It is used to weld car body panels, doors, chassis components, etc. It can create an instant joint in the car body, which is strong enough. It is a preferred method because of its speed, minimal HAZ, and aesthetic appeal. Thousands of laser joints are made in manufacturing a single car.
Other than that, it is used in connecting cells, modules, and busbars of battery packs. Components of the exhaust system also require laser welding.
For repairing a car’s body and welding panels and parts, laser welding is used. Thus, it is an important component of modern automotive manufacturing.
Aerospace
In the aerospace industry, laser welding is used to weld lightweight materials. It can join the panels and complex parts. Be it turbine, hydraulic systems, airframes, fuel tanks, or other components, laser welding is the best choice. It offers excellent strength without affecting the properties of the lightweight material.
Medical Devices
Medical devices require extremely precise and clean welding joints, which are only possible through laser welding. It is used to make surgical instruments, tools, diagnostic equipment, medical implants, etc. Laser welding gives a perfectly clean weld that is strong and precise enough.
Electronics/Electrical Equipment
For tiny electronic components, laser welding is used. It is a safe way to join them with other components on the PCB without damaging them.
Because of the controlled heat, the nearby electronic components also remain safe. Sensors, semiconductors, and other delicate components are joined using a laser welder to ensure clean, strong, and reliable joints.
Jewelry Making
The delicate jewelry items can’t handle heat stress. That’s why common welding methods fail here.
Laser welding can precisely join tiny parts of the jewelry with extreme precision. It does not damage the nearby parts or put them under heat stress. They remain intact during the welding process. Jewelers also use laser welding to repair jewelry items.
Part 4: How to Choose the Right Laser Welder
A laser welding machine could be a new welding technique for even experienced welders. It’s better to understand the nitty-gritty and know the key factors to consider while buying a laser welder.
Application
The first thing you need to consider is the purpose of purchasing a laser welder. Consider the applications where you want to use the laser welder, the materials you want to weld, the material thickness, etc.
For different applications, you will have to go with different laser welders. Each welder has its specifications, limitations, and features. Consider the use cases while choosing a laser welder.
Type of Laser
Laser welders use a laser source, and based on that, we can classify laser welders into four types.
The most popular laser welder is the Fiber Laser Welder. It uses a doped optical fiber for laser generation and amplification. It’s a highly efficient laser welder that requires low maintenance. It offers incredible weld quality and can be used on a wide range of materials. Keep in mind that fiber laser welders are expensive, but they are ideal for high-volume applications, such as mass manufacturing.
Then, we have CO2 laser welders. They use a gas mixture to produce laser beams through electrical discharge. They offer incredible power, which is the reason they are used for industrial applications. They are suitable for welding non-metals, such as joining non-metal parts of a car, such as a bumper.
Nd:YAG laser welders have been an industry standard before fiber lasers. They use a solid crystal for the generation of laser beams. They are ideal for pulsed laser welding. Their high power is suitable for creating immense energy pulses for spot welding and other applications. They can be used for jewelry repair, precision welding, medical device manufacturing, etc.
The last one is the Diode Laser Welder. They used high-powered laser diodes to generate laser beams. They are compact and energy-efficient, and perfectly suitable for small applications. They are quite affordable compared to other laser welders. But their applications are limited because of their limited power.
Power
The power of the laser welding machine defines its ability to weld different materials. For instance, a welder with low power is suitable for delicate applications. However, a welding for high power is suitable for thick metals and heavy-duty applications.
The power of a laser welder machine is mentioned in watts. It gives an idea of what the machine can weld and where it can be used. For general-purpose and DIY applications, 1000-1500W is more than enough. For thick materials over 5mm, you need more power. Go with 2000W or higher.
Do not confuse laser power with the rated input power of the machine. Laser power is different from the electrical input power.
Welding Mode
Laser welding machines operate in different modes. Most machines have a single mode, while some have multiple modes for versatility.
All these modes are used for different applications and purposes. The Continuous Wave (CW) welding mode is suitable for continuous welding. It offers a steady beam of laser to weld thick materials at a fast rate.
The Pulsed Welding mode delivers a short burst of laser light with intense energy. It is suitable for delicate materials where heat control is important. It can join metal pieces with low heat input.
The Spot Welding mode is used for joining metal sheets. It welds materials with low heat input and at an incredible speed. It’s an instant process; as soon as the high-energy laser beam strikes the metal, a joint is created.
There are also conduction and keyhole welding modes. The first one offers low power density, and the heat is transferred through thermal conduction. It creates shallow and wide welding with low penetration. It is suitable for welding thin metal sheets, electronic components, and medical devices.
The keyhole mode delivers high power for deep and narrow welds. Its power density is so high that it can melt or vaporize the material quickly. It is an ideal option for applications where high penetration is needed.
According to the application, users need to select the welding machine that offers the desired welding modes.
Safety
While buying a laser welding machine, it is a must to look at the safety features it offers. You can’t compromise on safety. You can look at the electrical safety, temperature monitoring, emergency stop, etc.
Part 5: Why You Should Opt for xTool Metalfab Laser Welder
xTool Metalfab is an innovative laser welding machine designed to make laser welding accessible, affordable, and user-friendly. It offers industrial power in a compact machine that you can operate from a garage.
It makes metalworking easier and opens doors to limitless creativity. With its advanced technology and exceptional precision, you’ll get incredible results every time you grab the laser torch.
It is a fiber laser machine available in two variants, 800W and 1200W. They can do continuous welding, pulsed welding, and spot welding. Users can use the machine on stainless steel, aluminum, carbon steel, nickel alloy, brass, titanium, magnesium, etc.
Here’s why you should choose xTool Metalfab.
3-in-1 Laser Machine
xTool Metalfab is a 3-in-1 laser machine. It is a laser welder, CNC cutter, and CNC cleaning machine. It’s a complete laser metal workshop to meet all your needs for metal fabrication. You can use it as a handheld laser for welding and cleaning. While the CNC machine is for automated cutting and cleaning.
Incredible Speed
It offers incredible speed, which is 8X that of a TIG welder. It can quickly weld metal pieces with extreme precision and quality. It can weld metals up to 5mm thick in a single pass. You get deep and narrow welds that look aesthetically pleasing.
User-friendly
xTool Metalfab is made to make metalworking easier. It is a user-friendly machine that anyone can use without any expertise or prior experience. It requires minimal effort to master the welding, cutting, and cleaning processes. The software of the machine is also beginner-friendly. Users can choose the optimal settings with one click and get started in no time.
High-end Technology
The machine is equipped with high-end technology. It contains industrial-grade Coherent chips that convert electrical energy efficiently. Not only can you save on electrical energy, but you can also save on the shielding gas through its gas-saving solution.
It contains dual cameras to give you a complete panoramic and close-up view. It can help in optimizing the layout to save material during cutting.
Safe Design
xTool Metalfab has Class 4 Laser Safety certification. It is equipped with excellent safety features, such as an emergency stop switch, grip detection, electrical safety design, 3-zone real-time temperature monitoring, lid closure detection, laser filtering cover, etc. It is a safe laser welding machine for beginners.
Part 6: Conclusion
Laser welding is a remarkable technology gaining popularity over time. Because of its unmatchable precision, clean welds, high speed, and other benefits, it is the preferred choice for various applications. If you are thinking of getting a laser welder, make sure to consider the important factors we have discussed in the article. By keeping those factors and features in mind, you can select the right welder machine for your endeavors.
