Laser welding: areas of application, modes of operation & devices

 

Laser Welding: The Advantages at a Glance

Laser welding, often referred to as laser beam welding, describes a welding process that uses laser energy to create weld joints, primarily between metallic workpieces. Compared to other welding techniques, laser beam welding has numerous advantages:

  • Precise energy input even for the finest structures
  • Very small heat-affected zones
  • High mechanical strength of the seam
  • Contactless laser welding without exerting force on the workpiece
  • Good process control for consistent manufacturing quality
  • Good accessibility
  • Suitable for welding complex materials, such as aluminum or titanium

Whether laser beam welding, additive manufacturing or laser hardening – ALPHA LASER offers comprehensive laser systems for various applications and industries.

 

Suitable products for laser welding

ALM AL-CROSS Series ALFlak Max
ALFlak | ALFlak Fiber AL-Serie AL-IN
AL-TW ALW / ALW Fiber ALV / ALV Fiber
AL-Q VLO 60 ALO
AL-SWS

 

Laser welding: functional principle & areas of application

In laser welding, welding is carried out using laser energy. The laser beam is optically focused so that a high energy input melts a very small area. During laser welding, the weld pool is protected from oxidation by shielding gas, usually argon. In the weld pool, the workpieces and the filler metal join to form a weld seam. By focusing the laser beam, the heat input is limited to a small part of the workpiece, which means that the weld seam cools down quickly - a result of the high temperature gradient between the welded area and the entire workpiece.

Due to the precise processing with very low distortion and the high welding speed that can be achieved with the laser systems, laser beam welding is used in numerous areas of application, including

  • Automotive industry
  • mechanical engineering
  • precision engineering
  • shipbuilding
  • toolmaking
  • Medical and dental technology
  • Jewelry industry
  • Sheet metal processing
  • steel construction
  • Aerospace industry
  • Casting repair
  • Sensor production
  • Repair welding

Laser welding: these types are available

Different laser welding techniques are used depending on the area of application. These differ primarily in the shape of the resulting weld seam by setting the welding parameters accordingly. The following laser welding processes exist:

  • Deep penetration welding: In deep penetration welding, the laser intensity is particularly high so that the vaporization effect occurs and metal plasma is formed. Deep penetration welding is the most common variant of laser welding.
  • Micro welding: Micro welding refers to welding processes in which components of very small sizes are welded together. One form of micro-welding is spot welding; resistance brazing and enameled wire welding also fall into this category.
  • Spot welding: Small welds with a diameter of less than 0.1 millimeters are produced with a low heat load during spot welding. This creates a weld seam consisting of many small spot welds. This process is suitable for small geometries.
  • Seam welding: Seam welding is a welding process in which the laser source continuously produces a weld seam. This ensures a high welding speed, which is required for joint welding in overlap or butt welding, among other things.
  • Heat conduction welding: Heat conduction welding offers a very flat weld. As the laser intensity remains below the threshold, there is no deep penetration welding. 
  • Powder deposition welding: Laser deposition welding is a type of welding in which metal powder is welded onto a component using laser energy. A smooth layer is created with little heat input. It enables different layer thicknesses and 3D volumes and is used in particular in the automotive industry, the energy sector and toolmaking.
  • Scanner welding: With scanner welding, the laser beam is positioned without having to align the workpiece or the processing head - the laser beam is aligned using a rotating mirror.

 

Precise & fast laser beam welding with laser systems from ALPHA LASER

ALPHA LASER has set itself the task of making the laser welding process ever more precise, application-oriented and faster. With ALPHA LASER laser systems, numerous materials, including metallic materials with high thermal conductivity or high melting temperatures, can be welded in no time at all.

These are the features that make ALPHA LASER laser welding systems stand out:

  • high laser energy
  • ease of use
  • Flexible adjustment of welding parameters, including laser focus, workpiece thickness & laser pulse
  • pinpoint energy input thanks to precise fiber lasers and Nd:YAG lasers
  • low heat input
  • No material distortion
  • clean & precise result as well as slim seam geometry on butt seams, overlap seams or fillet welds at an appropriate welding speed
  • can also be used for powder deposition welding, depending on the laser system
  • Maximum flexibility thanks to automated, semi-automated or manual laser welding
  • depending on the laser welding machine, mobile laser welding is also possible
  • Pulse welding & CW welding
  • Video sequences

 

Flexible laser welding with manual, automated & semi-automated lasers

ALPHA LASER Lasermaschinen schweißen mit und ohne Zusatzwerkstoff bzw. Drahtförderung automatisiert, halbautomatisiert und manuell.

  • Automated laser welding: Automated laser welding systems use our WINLaserNC software, with which the welding process (paths and laser parameters) is programmed or entered. The laser welding machine feeds the filler material using an automatic wire feed system. This procedure is ideal for welding large areas or frequently recurring components. The process is controlled either via the binoculars or via our HDMI camera with monitor.
  • Semi-automated laser welding: With semi-automated laser welding, the operator has the option of moving one or more axes automatically at a preset speed, so that he only has to make curves or small corrections with the joystick of the laser welding machine.
  • Manual laser welding: Our manual welding lasers provide you with maximum flexibility for laser welding. In manual laser welding, the filler material is fed in by hand and the welding process is monitored via the binoculars.

Laser welding: The most frequently asked questions

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