Advantages And Disadvantages of Laser Welding

Laser welding is a welding technique that uses a laser beam to focus a heat source to join multiple pieces of metal. Manufacturers and sheet metal processors are increasingly relying on this high-tech process for welding with laser technology for higher quality, faster throughput, and lower post-processing costs. Want to learn more about laser welding before getting started? Read on to learn more about the advantages and disadvantages of laser welding.

How does laser welding work?

Laser welding or laser beam welding is a process that uses a laser-focused heat source to melt materials. Laser welding operates in two fundamentally different modes: conduction-limited welding and deep-hole welding. The mode of interaction of the laser beam with the material it is welding will depend on the power density at which the beam hits the workpiece. The working principle of laser welding is to focus a high-power-density laser and apply heat to the joint between two metal surfaces. When the metal surface absorbs the laser, the material is heated and melted to form a weld between the two surfaces to complete the welding.
Laser welding has higher welding precision and quality. Since the laser itself generates very little heat, the weld seam produced after laser welding is also relatively small, which makes laser welding especially suitable for thinner materials, such as electronics or glass/metal seals. Whereas when welding thicker materials, narrow and deep welds are produced between square-edged parts. Today, modern laser welding applications incorporate advanced optics that allow the use of programmable robots to pinpoint an area in the workpiece.

Advantages of laser welding

Laser welding has many advantages over traditional welding techniques. Firstly, laser welding can be done without any additional tools or fixtures, resulting in more precise results. In addition, lasers can reach incredibly high temperatures, so laser welding also produces very strong and durable welds.

Higher Accuracy

Laser welding produces a very narrow laser beam that can be focused very precisely on the area to be welded, even in areas as small as millimeters in diameter. In addition to more precise control of the welding process, it also avoids wastage and errors of welding material and ensures consistent quality.

High-quality welds

One of the main advantages of laser welding is that it produces higher-quality welds. That’s because laser welding creates a narrower and deeper weld than other methods, creating a stronger bond between the two pieces of metal and can withstand extreme temperatures and harsh environments. The uniform pulse of laser welding results in a very clean seam after laser welding without the beading or burrs that are inevitable in gas-shielded or electric welding.

The laser increases welding speed

Laser welding is many times faster (up to 5 to 10 times faster) than traditional methods. Welding speeds vary depending on the type and power of the laser generator used. High welding speeds allow more parts to be produced per hour, which means faster turnaround times and higher productivity. Additionally, laser welding can be integrated with automated equipment, which allows them to run for longer periods.

Reduce post-weld treatment costs

The process of traditional welding and laser welding is to transfer heat at the junction of two surfaces. When welding using traditional methods, materials can be subject to bending, stress, and other negative effects. However, the laser has a huge power density, the width of the heat-affected zone on both sides of the weld is narrow, and the thermal damage and performance loss of the material near the weld are reduced. The deformation of the samples is therefore less than that of samples welded by many other processes.
Grinding is usually not required after laser welding, which can significantly reduce post-processing costs. Having such a decorative weld seam also helps to enhance the appearance of the product and make a good first impression on the customer.

Versatility

Laser welding is extremely versatile, and different laser units are good at welding different kinds of things. For example, laser welding can be performed on a variety of metal materials, including mild steel, stainless steel, and titanium. Laser welding can be used to weld thick steel plates used in the shipping industry, to weld precious metals used in jewelry, or to weld copper contacts on electric car batteries. It can reach hard-to-reach places, realize non-contact long-distance welding, and has great flexibility. Laser welding is very suitable for the assembly and welding of miniature and small workpieces produced in large quantities.

Greater security

Another advantage of laser welding as a non-contact joining process is safety. Lower-power laser welding machines are less of a safety risk and are usually portable, using a hand-held welding head to start welding; higher-power laser welding machines are remotely controlled, allowing workers to direct the laser beam without needing to be near the welding area. Additionally, laser welding produces less fume than other methods, which helps reduce workers’ risk of respiratory illness and improves air quality.

Disadvantages of laser welding

Despite the many benefits of using laser welding, there are also some disadvantages associated with laser welding that should be considered before investing in this technology. This helps you gain a better understanding of your machines and reduces costs associated with machine breakdowns.

High upfront costs

The main disadvantage of laser welding is the high initial cost. The initial acquisition cost of a laser unit is typically double or triple that of conventional systems, requiring a significant one-time investment. It can also be costly to train employees to use them. Additionally, maintenance and repair costs for laser welding machines can also be higher than other types of welding equipment. But laser welding pays for itself quickly with its superior speed, precision, and versatility. The efficiency orientation of laser welding enables companies to optimize production, reduce material waste, and increase overall profitability.

Low backlash tolerance

Low clearance tolerance means that the assembly accuracy of the weldment is high, and the position of the beam on the workpiece cannot have obvious deviations. This is because the spot size of the focused laser is small and the weld seam is narrow, which is prone to welding defects when the workpiece is assembled or the beam positioning is inaccurate. Low backlash tolerances mean you need to ensure that your upstream processes/suppliers can reliably meet tight tolerance levels.

Training required

In manufacturing and metal fabrication, laser welding has become a transformative technology, offering unparalleled precision and efficiency. However, realizing the full potential of a laser welding machine requires more than purchasing equipment. It requires extensive operator tIn modern training to ensure safe operation, optimize performance, and unlock the myriad benefits it offers. Operator training sessions can add to the overall cost of a laser welding machine.

Limited application

While a laser welding machine offers excellent advantages in many applications, it also has certain limitations, such as it is less suitable for welding thicker materials and cannot be used for certain types of joints. Also, certain materials, such as highly reflective surfaces, may not be suitable for laser welding. In such cases, alternative welding methods such as arc welding or e-book welding may be more appropriate. It is recommended that before a welding project begins, its specific requirements are assessed and an expert consulted to determine the most suitable welding method.

There is a security risk

While laser welding has revolutionized the welding industry with its precision and efficiency, it still comes with certain safety risks. For example, when using a laser welding machine, the intense laser beam emitted during the welding process can cause severe burns or permanently damage the eyes if proper eye protection is not used.

When using a laser welding machine, comprehensive safety protocols, proper training, and regular maintenance of the equipment are required to minimize the risks associated with laser welding. Laser welding requires more protective measures than other welding methods.

Summarize

Laser welding is an impressive technology that can provide manufacturers with efficient and low-cost welding methods. While there are some drawbacks to this process, such as low clearance tolerances during welding, these can be overcome with little care. If you’re in a business looking for a reliable way to join metals quickly and precisely, then laser welding might be just what you need!
To learn more about laser welding in action, watch this video. If you have more questions, AccTek Laser is happy to discuss your specific application with you to help you make the right decision.

Laser Equipment

Contact information

Get Laser Solutions