Zwei Fallstudien demonstrieren konkrete Anwendungen der ALPHA LASER Technologie in medizintechnischen Bereichen:

Einsatzgebiete & Anwendungsbeispiele von Laser in der Medizintechnik

Das Spektrum möglicher Anwendungen von Laserschweißen in der Medizintechnik hat sich in den letzten Jahren erheblich erweitert und umfasst heute nahezu alle Bereiche der Fertigung medizinischer Geräte und Komponenten. Von lebensrettenden Implantaten bis hin zu präzisen Diagnoseinstrumenten ermöglicht Laserschweißtechnologie die Herstellung komplexer medizinischer Geräte:

• Implantierbare Medizinprodukte: Herzschrittmacher, Cochlea-Implantate, Neurostimulatoren und implantierbare Defibrillatoren profitieren von hermetischen Laserschweißverbindungen, die langfristige Zuverlässigkeit im Körper gewährleisten.
• Chirurgische Instrumente: Laparoskopische Werkzeuge, mikrochirurgische Instrumente und Endoskope erfordern Schweißnähte für optimale Funktionalität und Sterilisierbarkeit.
• Minimal-invasive Systeme: Katheter, intravenöse Leitungen und Stentsysteme nutzen Laserschweißtechnologie für die Verbindung miniaturisierter Komponenten.
• Diagnostische Geräte: Sensoren, Chips und elektronische Baugruppen in medizinischen Analysegeräten werden durch präzise Laserschweißungen zusammengefügt.
• Dentalmedizin: Zahnimplantate kieferorthopädische Apparate und dentale Instrumente profitieren von den biokompatiblen und präzisen Schweißverbindungen.

Reinraumtaugliche Lösungen

Medizintechnische Fertigung muss häufig in kontrollierten Atmosphären stattfinden, die spezielle Anforderungen an Partikelemission und Luftströmung stellen. Die ALPHA LASER Lasersysteme können entsprechend für lüfterlose Kühlsysteme, minimierte Geräuschentwicklung und reinraumkonformes Design konfiguriert werden.

Reinraum schweißen

Reinräume erfordern baulich geschlossene Abgrenzungen und müssen strenge Reinheitsrichtlinien erfüllen. Mit Hilfe von Reinlufttechnik werden Partikel aus der Luft gefiltert und sämtliche Personen und Materialien gelangen nur über eine Schleuse in den Reinraum. Für Schweißarbeiten in einem Reinraum eignet sich Laserschweißen besonders, da es sauberes Arbeiten ohne offene Flammen, Funken und Schweißspritzer ermöglicht. Der Schweißprozess selbst ist mit Lasertechnologie nahezu partikelfrei und so präzise, dass Nachbearbeitungen selten nötig sind, was das Risiko einer erneuten Verunreinigung minimiert.

Sauberraum schweißen

Sauberräume oder Weißräume und die Personen und Materialien, die sie betreten, unterliegen ebenfalls Reinheitsrichtlinien, im Gegensatz zum Reinraum sind Reinlufttechnik und Schleusen jedoch nicht vorgeschrieben. Ein Sauberraum verursacht weniger Kosten als ein Reinraum und lässt mehr Spielraum für Fertigungs- und Schweißprozesse. Die Vorteile des Laserschweißens im Reinraum treffen aber genauso auf den Sauberraum zu.

Prozessstabilität

Konstante Schweißqualität über lange Produktionszyklen sind in der Medizintechnik nicht verhandelbar. Bereits einzelne Qualitätsabweichungen können kostspielige Nachvalidierungen zur Folge haben. ALPHA LASER hat speziell für diese Anforderungen das WINLaser^® 5 Steuersystem entwickelt, das umfassende Prozessüberwachung mit OPC-UA-Schnittstelle für moderne Fertigungsumgebungen und Industrie 4.0 bietet. In Verbindung mit stabilen Faserlaserquellen entstehen dokumentierbare und skalierbare Produktionsprozesse.

Schweißen von High-Tech-Werkstoffen

Die Medizintechnik setzt verstärkt auf hochentwickelte Materialien, die außergewöhnliche Eigenschaften mitbringen. Speziallegierungen stellen jedoch besondere Anforderungen an den Schweißprozess und sind wesentlich anspruchsvoller zu bearbeiten als herkömmliche Konstruktionswerkstoffe. High-Tech-Materialien erfordern präzise abgestimmte Laserparameter, spezielle Schutzgasatmosphären und angepasste Oberflächenvorbereitungen. ALPHA LASER hat durch praktische Anwendungen in zertifizierten Produktionsumgebungen nach ISO 13485 über Jahre hinweg wertvolles Know-how auf diesem Gebiet aufgebaut. Die entwickelten Prozessparameter sind in realen Fertigungsszenarien erprobt und gewährleisten reproduzierbare Ergebnisse bei höchsten Qualitätsanforderungen. Zahlreiche MDM-Unternehmen setzen unsere Lasertechnologien bereits produktiv ein.

Laserschweißen Nitinol

Nitinollegierungen sind für ihre Formgedächtniseigenschaft und Biokompatibilität beliebte Werkstoffe der Medizintechnik, bringen aber besondere Herausforderungen in der Verarbeitung mit sich. Gepulstes Laserschweißen bringt dabei einzigartige Vorteile mit sich:

• feine Fokussierung des Laserstrahls für präzise und saubere Schweißnähte
• geringe Wärmeeinflusszone
• flexible Parameter für unterschiedliche Materialien und Schweißaufgaben, einschließlich der Verbindung von Nitinol mit anderen Materialien
• hohe Biokompatibilität, da auf Lote oder Flussmittel verzichtet werden kann
  
   

Präzisionsschweißen für hochgenaue Arbeitsabläufe

Unsere Lasersysteme erreichen Schweißungen bis zu 0,1 mm und darunter mit konsistenter Wiederholbarkeit von Teil zu Teil. Die Punktschweißungen erfolgen jedes einzelne Mal genau dort, wo sie erwartet werden und hinterlassen Nahtlinien, die so fein sind, dass sie als Ätzungen durchgehen könnten. Dieser Grad an Präzision eignet sich für die filigransten Komponenten der Medizintechnik und macht Laserschweißen zum Goldstandard im Herstellungsprozess.

Diese Systeme sind zum Laserschweißen von Aluminium geeignet

TÜV-konformes Schweißen an Auto & Oldtimer

Schweißarbeiten am Auto unterliegen den Vorschriften des TÜV. Vor allem beim Kfz-Schweißen von Oldtimern gelten besondere Auflagen. So können beispielsweise Schweißverfahren, Schweißparameter oder sogar die Qualifikation des bzw. der Schweißenden vorgegeben sein. Da diese sich je nach Organisation (TÜV, DEKRA, GTÜ, KÜS), Bundesland und Fahrzeug unterscheiden können, empfiehlt es sich, vorher bei der zuständigen Bearbeitungsstelle die genauen Auflagen zu erfragen.

Wichtig ist: Tragende oder sicherheitsrelevante Bauteile sollten nicht repariert, sondern ausgetauscht werden! Für alle anderen Bauteile empfehlen wir den Einsatz von Laserschweißgeräten, da diese besonders stabile Schweißverbindungen schaffen und die Energie ganz gezielt nur dort einbringen, wo es notwendig ist.

The anniversary was an unforgettable event, leaving all guests with lasting memories of inspiring conversations, fresh ideas, and excitement for what lies ahead.

A milestone, celebrated in the best possible way!

Customer Benefits at a Glance

Our customers benefit directly from UMATI integration:

• Less integration effort: Unified interface instead of costly single solutions

• More transparency: Live machine data for better decision-making

• Higher efficiency: Reduced downtime and optimized production processes

• Flexibility: The ALPHA LASER system “speaks the language” of the entire production line

• Scalability: New machines can be integrated into the system with minimal effort

Practical Application Examples
What does this look like in practice? Some typical scenarios:

• A factory connects multiple laser welding systems from different suppliers in one dashboard full real-time overview

• Production managers monitor machine status and performance on tablets fewer unplanned downtimes

• Customers integrate our systems seamlessly into existing Smart Factory platforms, without extra costs

• Industries such as medical technology or sensor technology benefit from the simple integration of specialized systems into highly complex workflows
  
   

UMATI as an Industry Standard
The significance of UMATI goes far beyond individual companies. For the entire machine-building sector, UMATI is a strategic milestone:
 

• Fewer proprietary interfaces lower costs, more standardization

• Easier integration for small and medium-sized enterprises

• Better scalability for international production networks
  
   

Conclusion: Future-Proof Manufacturing with UMATI & ALPHA LASER
The future of manufacturing is open, connected, and efficient. With UMATI and our ALPHA LASER solutions, we create the foundation for machines and systems to work together seamlessly.
 

• “With UMATI, our laser welding machines speak the universal language of Industry 4.0.”

• “Seamless connectivity, zero hassle: UMATI brings our machines into your digital ecosystem.”
   

Anyone who wants to make their production future-proof cannot avoid open standards – and this is exactly where ALPHA LASER with UMATI comes in.

Looking Ahead

This Experten & Technologietag underscores our commitment to co-creating laser solutions that meet practical, diverse industrial requirements. Your feedback helps us prioritize features—whether added automation, power scaling, or software enhancements.

A heartfelt thank you to all 80 attendees from 34 companies—your participation energized the event. We look forward to keeping the momentum going: follow-up visits, additional demos, or tailored consultations at your location.

Our customers benefit directly from UMATI integration:

• Less integration effort: Unified interface instead of costly single solutions

• More transparency: Live machine data for better decision-making

• Higher efficiency: Reduced downtime and optimized production processes

• Flexibility: The ALPHA LASER system “speaks the language” of the entire production line

• Scalability: New machines can be integrated into the system with minimal effort

Practical Application Examples
What does this look like in practice? Some typical scenarios:

• A factory connects multiple laser welding systems from different suppliers in one dashboard full real-time overview

• Production managers monitor machine status and performance on tablets fewer unplanned downtimes

• Customers integrate our systems seamlessly into existing Smart Factory platforms, without extra costs

• Industries such as medical technology or sensor technology benefit from the simple integration of specialized systems into highly complex workflows
  
   

UMATI as an Industry Standard
The significance of UMATI goes far beyond individual companies. For the entire machine-building sector, UMATI is a strategic milestone:
 

• Fewer proprietary interfaces lower costs, more standardization

• Easier integration for small and medium-sized enterprises

• Better scalability for international production networks
  
   

Conclusion: Future-Proof Manufacturing with UMATI & ALPHA LASER
The future of manufacturing is open, connected, and efficient. With UMATI and our ALPHA LASER solutions, we create the foundation for machines and systems to work together seamlessly.
 

• “With UMATI, our laser welding machines speak the universal language of Industry 4.0.”

• “Seamless connectivity, zero hassle: UMATI brings our machines into your digital ecosystem.”
   

Anyone who wants to make their production future-proof cannot avoid open standards – and this is exactly where ALPHA LASER with UMATI comes in.

Our customers benefit directly from UMATI integration:

• Less integration effort: Unified interface instead of costly single solutions

• More transparency: Live machine data for better decision-making

• Higher efficiency: Reduced downtime and optimized production processes

• Flexibility: The ALPHA LASER system “speaks the language” of the entire production line

• Scalability: New machines can be integrated into the system with minimal effort

Practical Application Examples
What does this look like in practice? Some typical scenarios:

• A factory connects multiple laser welding systems from different suppliers in one dashboard full real-time overview

• Production managers monitor machine status and performance on tablets fewer unplanned downtimes

• Customers integrate our systems seamlessly into existing Smart Factory platforms, without extra costs

• Industries such as medical technology or sensor technology benefit from the simple integration of specialized systems into highly complex workflows
  
   

UMATI as an Industry Standard
The significance of UMATI goes far beyond individual companies. For the entire machine-building sector, UMATI is a strategic milestone:
 

• Fewer proprietary interfaces lower costs, more standardization

• Easier integration for small and medium-sized enterprises

• Better scalability for international production networks
  
   

Conclusion: Future-Proof Manufacturing with UMATI & ALPHA LASER
The future of manufacturing is open, connected, and efficient. With UMATI and our ALPHA LASER solutions, we create the foundation for machines and systems to work together seamlessly.
 

• “With UMATI, our laser welding machines speak the universal language of Industry 4.0.”

• “Seamless connectivity, zero hassle: UMATI brings our machines into your digital ecosystem.”
   

Anyone who wants to make their production future-proof cannot avoid open standards – and this is exactly where ALPHA LASER with UMATI comes in.

Customer Benefits at a Glance

These advantages and disadvantages apply to the various welding processes for cast iron:

Passende Produkte finden Sie hier.

1. Pulsspitzenleistung
2. Pulsdauer
3. Pause
4. Mittlere Leistung
5. Pulsenergie
6. CW-Leistungen

Vorteile des gepulsten Laserschweißens:

• geringe Wärmezufuhr
• Reduzierung thermischer Verformungen
• saubere, kontrollierte Energieabgabe
• perfekt abgestimmte Prozesse von Anfang an

This milestone wasn't simply a celebration of our achievements. It was a heartfelt acknowledgment of the individuals who have made those achievements possible, reinforcing that our commitment to technological leadership always starts with our people, our partners, our colleagues, who are and always will be at the core of our journey and of our decisions.

UMATI in ALPHA LASER AL-Q Systems

At ALPHA LASER, we focus on future-proofing and open standards. Our AL-Q laser welding system is often integrated into highly specialized production environments. This is where UMATI shows its strengths:

• Seamless communication between our systems and the customer’s IT infrastructure

• Easy integration without costly custom solutions

• Flexibility: The ALPHA LASER system can easily be embedded in complex manufacturing environments

Collaboration & Networking

More than a showcase, the event fostered meaningful dialogue:

• Guided factory tours invited technical deep-dives into system architecture.
• Breakout sessions and lunch allowed participants to engage directly with product experts.
• Open Q&A formats prompted technical brainstorming—including discussions on real-world integration, fixture design, and troubleshooting strategies.

The authentic exchanges highlighted our customers’ real needs—informing future product improvements and use-case support.

At ALPHA LASER, we focus on future-proofing and open standards. Our AL-Q laser welding system is often integrated into highly specialized production environments. This is where UMATI shows its strengths:

• Seamless communication between our systems and the customer’s IT infrastructure

• Easy integration without costly custom solutions

• Flexibility: The ALPHA LASER system can easily be embedded in complex manufacturing environments

At ALPHA LASER, we focus on future-proofing and open standards. Our AL-Q laser welding system is often integrated into highly specialized production environments. This is where UMATI shows its strengths:

• Seamless communication between our systems and the customer’s IT infrastructure

• Easy integration without costly custom solutions

• Flexibility: The ALPHA LASER system can easily be embedded in complex manufacturing environments

Are All Types of Cast Iron Weldable?

There are several types of cast iron, but not all of them are weldable:
•   Steel castings: Carbon contents of up to 0.5% may occur, which can make welding more complex. Nevertheless, most steel casting alloys can be welded with proper preparation
•   Aluminum cast (Alu cast): Weldable, but requires thorough preparation of the base material. Proper cleaning is essential; otherwise, weld defects may occur.

How to Weld Cast Iron

There are several ways to weld cast materials. Particularly with cast iron, the welding process can be very laborious – only gray cast iron is weldable, and even this material has a comparatively high carbon content, which causes it to harden and become porous quickly during welding. Despite this, gray cast iron can be welded using the following techniques:

• Hot welding:
  The material is heated to approx. 700 °C. This results in an almost invisible, color-matched weld seam.
  Advantage: very little impact on the base material.
  Important: slow, step-by-step cooling is necessary to prevent cracking.
• Cold welding:
  The cast iron is heated only to approx. 60–70 °C.
  Advantage: safer and easier to use than hot welding.
  Possible drawback: the weld seam may differ in color from the base material.
• Welding cast iron with shielding gas (MIG/MAG):
  MIG/MAG can also be used to weld cast parts. Welding wire and an electrode serve as filler materials. While the wire melts, an arc forms between the material and the electrode. Argon is commonly used as shielding gas.
• Welding cast iron with TIG:
  TIG welding is also a common method. As with MIG/MAG, an electrode is used, but it does not melt.
  Advantage: very clean weld seams.
  Drawback: significantly longer welding time.
• Laser welding of cast iron:
  Laser welding (laser beam welding) is a highly effective method for joining cast parts.
  In contrast to electrode welding, the use of shielding gas is optional. High welding speed and precise seams are further advantages of laser technology.

Beyond the festivities, we engaged in meaningful conversations about the technological advancements we’re pursuing and the challenges ahead. It wasn't just about celebrating the past 30 years; it was about recognizing the people who've been part of every step and shaping the ideas that will guide us forward.

Challenges in Modern Production

UMATI is an open, standardized communication standard based on OPC UA. It was developed by the German Machine Tool Builders’ Association (VDW) together with partners from the industry.

The advantages are clear:

• Plug & Play connectivity: Machines can be quickly and reliably integrated into existing systems

• Interoperability: Applicable across manufacturers and systems

• Real-time transparency: Machine status, performance, and diagnostic data available instantly

• Efficiency: Significantly less effort for setup and integration

• Future-proofing: Based on international standards and grows with Industry 4.0 requirements

Digitalization in Practice with WINLaser® 5 and WINLaser® CSP

Our new documentation and process control system WINLaser 5 attracted great interest from all those who value traceability, process reliability, and efficient production. With its intuitive user interface, automated workflows, and OPC UA support, WINLaser 5 offers real added value for industrial applications.

In addition, we presented the new WINLaser CSP (Connectivity Service Package) – a smart Industry 4.0 solution for centralized job management and system-wide integration of ALPHA LASER systems. It enables flexible and secure connectivity via OPC UA or REST API, meeting modern standards for data protection, cybersecurity, and digital communication.

Highlighted advantages:

• Automated welding workflows to reduce manual intervention

• Live monitoring for quality control during the welding process

• Structured documentation for series production and certification requirements

• Intelligent job management and connectivity with WINLaser® CSP for a future-ready production environment

Participants were able to test both systems hands-on and discuss their individual production requirements on site.

UMATI is an open, standardized communication standard based on OPC UA. It was developed by the German Machine Tool Builders’ Association (VDW) together with partners from the industry.

The advantages are clear:

• Plug & Play connectivity: Machines can be quickly and reliably integrated into existing systems

• Interoperability: Applicable across manufacturers and systems

• Real-time transparency: Machine status, performance, and diagnostic data available instantly

• Efficiency: Significantly less effort for setup and integration

• Future-proofing: Based on international standards and grows with Industry 4.0 requirements

UMATI is an open, standardized communication standard based on OPC UA. It was developed by the German Machine Tool Builders’ Association (VDW) together with partners from the industry.

The advantages are clear:

• Plug & Play connectivity: Machines can be quickly and reliably integrated into existing systems

• Interoperability: Applicable across manufacturers and systems

• Real-time transparency: Machine status, performance, and diagnostic data available instantly

• Efficiency: Significantly less effort for setup and integration

• Future-proofing: Based on international standards and grows with Industry 4.0 requirements

Cast Iron: More Than Just a Material

Cast iron is popular thanks to its robustness and long service life. The most relevant cast-iron types used in industry are gray cast iron and white cast iron.
They differ in the form in which carbon is present: gray cast iron contains carbon in the form of graphite, while in white cast iron the carbon appears as cementite.
The advantages of cast iron are clear: it is very similar to steel in its properties. In contrast to steel, cast iron expands and contracts significantly less, and scaling only begins at approx. 800 °C.

During this special day, we began with a chance for guests to explore Munich or dive into a closer look at the innovations we've developed together, showcasing the progress we've made with everyone's contribution.

As the day continued, we gathered in our courtyard tent, where the atmosphere came alive with a live band and later, a DJ who kept the celebration going. We made sure everyone felt valued with excellent food, drinks, and an environment that encouraged genuine connections.

Challenges in Modern Production

Many production facilities operate state-of-the-art machines, but networking them with ERP systems, MES, or Smart Factory platforms is difficult. Each machine “speaks” a different language, and integration projects are time-consuming and costly.

• Different interfaces complicate machine integration

• Lack of real-time transparency leads to downtime

• Every adjustment or expansion generates new costs

High Power Live Demonstrations

AL 2400 – 2.4 kW Fiber Laser System
A star of the day was the AL 2400 F, our high power fiber laser system delivering 2.4 kW, designed for faster, more efficient repair work in industrial metalworking. Featuring flexible configuration, motorized axes, and optional accessories like rotary chucks and tilt-turn objectives, it drew significant attention from participants in mold & die, maintenance, and onsite repair sectors.

AL Series (AL IN and AL)
We also showcased our standard AL series (100–900 W Nd:YAG and fiber models) and AL IN systems. Each system offers modularity through different laser sources, motion systems, and accessories—such as wire feed systems and ergonomic tables—to ensure bespoke configuration for varied welding tasks.

Attendees brought in their own parts for real-time repair demonstrations—highlighting the practical potential of modular laser systems in everyday industrial challenges.

Many production facilities operate state-of-the-art machines, but networking them with ERP systems, MES, or Smart Factory platforms is difficult. Each machine “speaks” a different language, and integration projects are time-consuming and costly.

• Different interfaces complicate machine integration

• Lack of real-time transparency leads to downtime

• Every adjustment or expansion generates new costs

Many production facilities operate state-of-the-art machines, but networking them with ERP systems, MES, or Smart Factory platforms is difficult. Each machine “speaks” a different language, and integration projects are time-consuming and costly.

• Different interfaces complicate machine integration

• Lack of real-time transparency leads to downtime

• Every adjustment or expansion generates new costs

Welding Cast Iron: Processes, Welding Systems & More

Cast iron is a proven industrial material – durable, robust and suitable for almost any application. When combined with other materials such as steel, iron, graphite, silicon or manganese, numerous cast varieties are produced, including cast iron, malleable cast iron and steel casting alloys. Although cast iron is one of the most important materials in industry, welding it can be difficult. This guide shows how cast iron can still be welded successfully, what is required, and what to pay attention to during the welding process.

(Lasergeschweißte medizinische Nadel. Mikroskopische Nahaufnahme einer sauberen Schweißnaht an einer medizinischen Nadel.)

Which Shielding Gas Is Best for Welding Stainless Steel?

While shielding gas is essential for both MIG and TIG welding, it is optional in laser welding. In most cases, the inert noble gas argon is used, although some applications are carried out with nitrogen. The required purity level of argon depends on the specific application and the desired weld quality.

Verzugsarmes Schweißen? Mit den ALPHA LASER Lasersystemen ist das möglich

Um Schweißverzug zu vermeiden, ist die richtige Schweißmethode das A und O. Die ALPHA LASER Laseranlagen eignen sich für zahlreiche Anwendungsbereiche und haben sich bereits in verschiedenen Branchen, wie der Automobilindustrie, der Batteriezellenfertigung, dem Werkzeug- und Formenbau und der Schmuckindustrie, bewährt. Vom Winkel bis zum Rahmen: Schweißen ohne Verzug ist mit den Lasersystemen von ALPHA LASER besonders einfach.

Ästhetisch einwandfreie Schweißergebnisse für Kfz

Ob bei neuen Autos oder beim Kfz-Schweißen von Oldtimern: Präzision ist das A und O beim Karosserie-Schweißen. Die geschweißten Teile müssen voll und ganz aufeinander abgestimmt sein, um die Passgenauigkeit zu gewährleisten. Ungenaue Schweißnähte können zudem die Stabilität negativ beeinflussen und im schlimmsten Fall zur Unbrauchbarkeit führen. Bei Oldtimern spielt zudem die Ästhetik eine große Rolle, was konturgenaues Schweißen umso wichtiger macht. Mit den Laserschweißgeräten von ALPHA LASER werden schon mit einem geringen Wärmeeintrag präzise Schweißnähte und stabile Verbindungen geschaffen. Dank der guten Prozesskontrolle und Zugänglichkeit können eine hohe Fertigungsqualität erreicht und feinste Strukturen punktgenau verschweißt werden. Hier kommen sehr häufig CuSi3-, G3Si1- oder AlSi12-Zusatzdrähte zum Einsatz.

These Devices Are Suitable for Laser Welding Stainless Steel

These Devices Are Suitable for Laser Welding Copper

Diese Laserschweißanlagen bietet ALPHA LASER an:

Diese Laserschweißanlagen bietet ALPHA LASER an:

Which Equipment for Which Laser Technique? Our Laser Systems

Note: Another welding method is MAG welding. However, this process is not suitable for stainless steel welding, as it uses active gases that can react with the surrounding atmosphere, potentially reducing the corrosion resistance of the material.

Welding Stainless Steel: Advantages & Disadvantages of Each Welding Process

Welding Copper: Available Welding Processes

Various welding techniques can be used to weld copper, including arc welding methods such as TIG and MIG welding, as well as laser welding:

• Welding copper using TIG welding: The TIG process is one of the most common methods for welding copper. The tungsten electrode generates an arc to the workpiece, heating the material in a controlled manner. To prevent the copper from reacting with ambient air, a shielding gas is used.
• Welding copper with the MIG process: MIG welding also operates with shielding gas. The filler material used in this process is a consumable electrode or welding wire. If additional materials are to be introduced via the filler material, MIG welding is a suitable choice.
• Laser welding copper: Laser welding, also known as laser beam welding, is one of the most advanced methods for processing copper. The energy is introduced into the workpiece in a highly targeted and controlled way, heating only the area to be welded. High process reliability and precision make laser-based metal processing one of the most popular welding technologies. When laser welding copper, the use of shielding gas is not required but possible.

Buy laser welding wire for copper

Fazit: Vorteile des Karosserie-Schweißens mittels Laser

Karosseriebleche zu schweißen, erfordert eine umfassende Vorbereitung sowie Präzision und Prozesskontrolle während des Schweißprozesses. Viele Schweißmethoden setzen jedoch langjährige Erfahrungen im Umgang mit den Schweißgeräten und Fachkenntnisse beim Auto-Karosserie-Schweißen voraus. Zudem eignet sich nicht jedes Schweißverfahren für jeden Werkstoff. Wer flexibel, kontrolliert und punktgenau schweißen möchte, setzt deshalb am besten auf das Laserschweißen.

Die Vorteile auf einen Blick:

• Unterschiedliche Materialtypen: Das Laserschweißen mit den ALPHA LASER Laseranlagen ermöglicht das Schweißen verschiedener Werkstoffe.
• Berührungslos: Vollkommen ohne Kraftausübung auf das Werkstück lassen sich die Autobleche schweißen Voraussetzung ist hier ein sogenannter Nullspalt zwischen den Fügepartnern.
• Hohe Prozesskontrolle: Präzision erfordert Kontrolle. Mit den Laseranlagen von ALPHA LASER werden gute Zugänglichkeit und Prozesskontrolle gewährleistet.
• Geeignet für nahezu jede Struktur: Ob dicke Autobleche oder feine Strukturen: Der punktgenaue Energieeintrag macht das Laserschweißen besonders flexibel einsetzbar.
• Stabile Verbindungen: Mit den Laserschweißanlagen kann eine hohe mechanische Festigkeit der Schweißnaht erreicht werden.
• Geringer Wärmeeinfluss: Dank minimaler Wärmeeinflusszonen werden Schweißnahtfehlern, wie beispielsweise Verformung oder Versprödung, entgegengewirkt.

Schweißen ohne Verzug: wie sich Schweißverzug vermeiden lässt

Verzug ist ein gängiges Phänomen beim Schweißen und bis zu einem gewissen Grad unbeeinflussbar, da der Wärmeeintrag benötigt wird, um die Werkstücke fest (stoffschlüssig) miteinander zu verbinden. Diese Maßnahmen können helfen, Verzug beim Schweißen zu minimieren:

• Das richtige Schweißsystem verwenden: Es gibt verschiedene Möglichkeiten, um Metallteile miteinander zu verbinden, doch nicht jedes Schweißgerät eignet sich für jede Anwendung. Laserschweißen bietet zahlreiche Vorteile und steht für einen verzugsarmen Schweißprozess. Auch die Flexibilität und die einfache Anwendung sowie die Möglichkeit, ein Schutzgas zu verwenden, machen das Laserstrahlschweißen zu einem bewährten Schweißverfahren.
• Geringer Wärmeeintrag: Die gezielte Bündelung der Laserstrahlung erhitzt das Material nur in der Schmelzzone, ohne das umliegende Material übermäßig oder unnötig zu erhitzen.
• Gepulstes Laserschweißen: Laserschweißgeräte verfügen über zwei unterschiedliche Betriebsmodi: CW-Modus (Continuous Wave bzw. Dauerstrich) oder Puls-Moduls. Im Pulsmodus kann der Wärmeeintrag noch besser kontrolliert werden, was einen deutlich geringeren Verzug mit sich bringt. Im CW-Modus muss die Bewegung sehr schnell erfolgen, um Verzug zu minimieren. Des Weiteren hilft das Wobbeln des Laserstrahls dabei die Energie gleichmäßig einzubringen was zu einer kontinuierlichen Schmelze führt, die wiederrum Verzug vorbeugt.
• Schweißparameter anpassen: Die Wahl der richtigen Schweißparameter ist für ein optimales Ergebnis maßgeblich. Geschwindigkeit, Temperatur, Stromstärke, Leistung oder Spannung sollten deshalb exakt auf die jeweiligen Materialien, die Materialstärke und den Schweißprozess abgestimmt werden. Umfassendes Fachwissen und Erfahrung sind hier nötig.
• Werkstücke fixieren: Auch eine fachgerechte Einpannung der Werkstücke ist wichtig, um einer ungewollten Bewegung des Werkstückes vorzubeugen.
• Die richtige Schweißreihenfolge bzw. Schweißstrategie wählen: Die richtige Schweißreihenfolge kann helfen, Schweißverzug und damit auch Formveränderungen entgegenzuwirken. Hier bietet es sich an, zuerst die äußeren Schweißnähte zu ziehen.
• Spannungen reduzieren: Schweißen und Härten ohne Verzug funktionieren in der Regel besser, wenn die Spannungen im Werkstück reduziert werden. Vorwärmen oder Spannungsarmglühen können dafür geeignete Wärmebehandlungsverfahren sein und so einen Verzug beim Schweißen vermeiden.
• Langsame Temperaturentwicklung: Wer den Wärmeeintrag kontrolliert, kann einem Verzug vorbeugen. Statt die Schweißnaht in einem Stück zu ziehen, können Pausen eingelegt werden, wodurch der Hitzeeintrag bei der Schweißung langsam, aber stetig erfolgt.
• Wechsel zwischen Anfang und Ende: Auch ein stetiges Wechseln zwischen dem Anfang und dem Ende der Schweißnaht kann dabei helfen, einem Schweißverzug vorzubeugen.
• Formieren der Schweißnaht: Das sogenannte Formieren, also das Umhüllen der Schweißstelle mit Schutzgas, trägt ebenfalls zur Temperaturkontrolle bei, wodurch Verzug verhindert werden kann.
• Abkühlung kontrollieren: Wer Spannungen und damit Schweißverzug vorbeugen möchte, sollte zum Abkühlen etwas Zeit einplanen: Ein langsames und kontrolliertes Abkühlen sowie ggf. ein Nachwärmen des Werkstücks zahlen sich in der Regel aus.
• Schweißstruktursimulation: Auch mit der besten Vorbereitung und in einem kontrollierten Schweißprozess kann es zu Schweißverzug kommen. Um das Bauteil am Ende wie geplant verwenden zu können, empfiehlt es sich daher, den Verzug beim Schweißen zu berechnen. Dies funktioniert am besten mit einer Schweißstruktursimulation.

Differences Between Laser Types

Different manufacturing processes require different types of laser systems. ALPHA LASER offers the following laser solutions:

• Open Laser Systems: These stationary, open laser systems provide excellent process control and precise focus on the welding area. They offer optimal accessibility for operators.
• Closed Laser Systems: ALPHA LASER’s stationary, closed laser systems ensure maximum safety. The ergonomic seating positions in these systems allow for comfortable operation in any environment.
  
  At ALPHA LASER, we use either Nd:YAG lasers or fiber lasers. Here’s what distinguishes these laser types:
   
• Nd:YAG Lasers: Nd:YAG lasers are solid-state lasers with a host crystal made of yttrium aluminum garnet. Compared to CO2 lasers, their wavelength is ten times shorter, allowing for highly precise work. These lasers are primarily used for manufacturing processes requiring fine structures and operate exclusively in pulsed mode. This type of laser is often associated with conduction welding.
• Fiber Lasers: Like Nd:YAG lasers, fiber lasers belong to the solid-state laser category. However, instead of yttrium aluminum garnet, they use a doped fiber core as the active medium. Fiber lasers are mainly applied in laser welding and laser cutting. They can be used for both CW (Continuous Wave) welding and pulsed laser welding, making them suitable for conduction and deep penetration welding.

•  

  • Mobile Laser Systems: Our mobile laser systems make laser techniques even more flexible. Depending on the application, location, and accessibility, mobile laser systems can be positioned individually—enabling their use in a variety of industries.

Versatility and Efficiency – what makes the difference?

The ALFlak 1200 Fiber Laser Welder is particularly versatile because it is suitable for both outer and inner diameters. This flexibility allows for a wide range of applications. Thanks to its precise control options over a joystick, welding processes can be performed with high accuracy. Another advantage of laser welding is that no subsequent heat treatment is required, which significantly speeds up the entire repair process.

Safety and Quality – what matters most?

In addition to technical performance, safety is also a top priority. Wearing laser safety glasses and utilizing the machine's integrated safety features are essential to protect the operator and their surroundings. Safety during laser welding is an integral part of the entire process.

CONCLUSION

The repair of turbine gearboxes impressively shows how laser welding technology not only saves time but also raises the precision and quality of repairs to a new level. The ALFlak 1200 Fiber Laser Welder from ALPHA LASER combines versatility, efficiency, and safety, thereby meeting the demands of modern industrial applications.

These Welding Processes Are Suitable for Stainless Steel

• MIG Welding Stainless Steel: The MIG welding process is well suited for thicker stainless steel components. Due to the high deposition rate of the welding wire, MIG welding is commonly used for steel fabrication. This technology is also one of the most popular methods for fillet welds, as MIG welding allows excellent control in adding filler material when welding stainless steel.

• Welding Stainless Steel with the TIG Process: TIG welding also uses shielding gas and is performed with a non-consumable tungsten electrode. In contrast to MIG welding, the TIG process is ideal for thin stainless steel workpieces and applications that require precision and a clean, aesthetic weld appearance.

• Electrode Welding for Stainless Steel: In addition to TIG welding with a tungsten electrode, stainless steel can also be welded using other consumable electrodes. Once the arc ignites, the electrode melts and forms a weld pool that joins the metal pieces together. This method is widely used in on-site work and for less controlled environments.

• Laser Welding Stainless Steel: Stainless steel can also be welded using laser beam welding. With the use of Nd:YAG lasers and fiber lasers, ALPHA LASER welding systems enable precision, safety, high peak pulse power, and highly focused energy input into the workpiece.

Caution: All welding methods involve reflection risks and an extremely bright plasma arc!

What to Consider When Welding Copper: Challenges & Risks

Welding copper requires a solid level of technical expertise. Is it pure copper or an alloy? Which welding process is most suitable, and what needs to be considered during the welding operation? The key aspects are explained below:

• Copper is a highly reflective material: When welding copper, high power levels are required to sufficiently melt both the base material and the filler material.
• Copper alloys: Depending on whether the workpiece is made of pure copper or a copper alloy, welding results can vary significantly and may require additional pre- or post-processing. It is therefore essential to identify the exact base material before starting the welding process.
• Single-phase & multi-phase alloys: The phase structure is also critical for copper welding. While single-phase metals are generally easy to weld, multi-phase alloys often cause difficulties. One example is a copper alloy containing lead. In such cases, brittle weld seams can occur because the melting point of copper (approx. 1085 °C) is significantly higher than that of lead (approx. 327.5 °C).
• Thermal conductivity: Copper has very high thermal conductivity, which may make it advisable to preheat the material. Whether preheating is required depends on the copper alloy, the workpiece thickness, and the selected welding process.
• Expansion & shrinkage: Anyone welding copper should always keep in mind that the metal expands significantly when heated and shrinks during cooling.
• Oxygen content: The oxygen content of the workpiece also influences the welding process. The lower the oxygen content, the easier copper welding becomes. Copper used for electrical applications often contains varying levels of oxygen, whereas copper used in plant engineering typically has a very low oxygen content.
• Exposure to ambient air: Copper is classified as a non-ferrous metal. When heated, non-ferrous metals tend to absorb surrounding gases, which can lead to weld seam defects. Depending on the welding method, it is therefore advisable to use a shielding gas, such as argon, when welding copper.
• Protective equipment: As with other metals, fumes may be released during copper welding that can pose health risks. Appropriate personal protective equipment, including respiratory protection, is therefore essential.

Welche Arten von Schweißverzug gibt es?

Abhängig von der jeweiligen Schweißnaht können verschiedene Arten von Schweißverzug auftreten. Dazu gehören:

• Querschrumpfung
• Längsschrumpfung
• Winkelverzug
• Neutralachsen-Verzug
• Kehlnaht-Verzug

Materialabhängigkeit beim Kfz-Schweißen

Schweißen am Auto bedarf einer umfassenden Vorbereitung. Da in der Automobilindustrie mit verschiedenen Materialien, wie Stahl, Aluminium und anderen Werkstoffen gearbeitet wird und jedes dieser Materialien spezifische Eigenschaften besitzt, muss die Materialabhängigkeit beim Kfz-Blech-Schweißen berücksichtigt werden. In diesen Bereichen spielt das Material eine große Rolle:

• Schweißnaht: Die Vorbereitung der Schweißnaht richtet sich nach dem jeweiligen Material. So sind bei Aluminium beispielsweise eine umfassende Reinigung sowie die Entfernung der Oxidschicht nötig, bevor der Schweißprozess beginnen kann.
• Wärmeeinflusszone: Die Wärmeeinflusszone betrifft den Bereich zwischen Schweißgut und Grundmaterial und unterscheidet sich je nach Materialtyp und Energieeintrag. Große Wärmeeinflusszonen können beispielsweise Verformungen oder Aufhärtungen (Versprödungen) nach sich ziehen. Je mehr Wärme eingebracht wird, um so größer ist die Wärmeeinflußzone!
• Schweißverfahren: Wer Schweißarbeiten am Auto selber machen möchte, sollte sich mit den verschiedenen Schweißmethoden auseinandersetzen. So werden MIG- oder MAG-Schweißen häufig bei Stahl eingesetzt, wohingegen das WIG-Verfahren beim Aluminium-Blech-Schweißen am Auto zum Einsatz kommt. Auch das Punktschweißen ist eine gängige Methode zum Auto-Karosserie-Schweißen. In der Industrie sind Laserschweißgeräte weit verbreitet, da dieses Verfahren präzise und leistungsfähig ist, aber hohe Sicherheitsstandards erfordert. Vorsicht: Bei allen Schweißverfahren besteht eine sehr hohe Reflektionsgefahr!
• Schweißzusatzwerkstoffe: Abhängig von Material und Schweißverfahren sind zudem die Zusatzwerkstoffe. So wird beispielsweise beim Karosserie-Schweißen mit Fülldraht ein Draht verwendet und beim Lichtbogenschweißen ein Flussmittel. Unser Tipp: Ein Kfz-Blech zu schweißen, funktioniert beim Laserschweißen ganz ohne Zusatz- oder Flussmittel.
• Schutzgas: Bei einigen Schweißmethoden, beispielsweise beim MIG- oder MAG-Schweißen, ist der Einsatz von Schutzgas notwendig. Auch beim Schutzgasschweißen sollte je nach Materialtyp das passende Gas gewählt werden. Das Laserschweißverfahren kann hier sowohl mit als auch ohne Zusatzgas (das ist abhängig von der genauen Anwendung am Kfz) durchgeführt werden.

Laser Processes in Industry & Technology: An Overview

Broadly speaking, the key laser techniques include laser welding, laser hardening, laser cutting, and additive metal manufacturing. Each technique utilizes different types of lasers depending on the process. Here are the most important laser techniques:

• Laser Welding: Laser welding uses laser energy (invisible to the human eye) to join various metallic materials. Similar to other welding methods like MIG and TIG welding, laser welding can use shielding gas but does not always require it. Due to its low heat input, precise, strong, and homogeneous weld seams, and excellent process control, laser welding is a widely adopted technology in many industries. For particularly fine structures, micro or precision welding is ideal.

• Laser Cladding: Also known as powder deposition welding, laser cladding is used for tool repair and protection. It restores worn-out areas and prevents corrosion by applying a thin layer of metal powder to the surface of tools and components. The laser beam fully and homogeneously melts the powder onto the surface.

• Laser Hardening: Similar to laser cladding, laser hardening protects stressed areas from wear and tear without adding extra material. By minimizing distortion, laser hardening enhances the durability of components while maintaining the core toughness of the metal. A subset of this technique is surface layer hardening, which increases the strength of workpieces without making the material brittle.

• Laser Cutting: Laser cutting enables precise cutting of various metal materials, regardless of thickness. This technique is especially trusted in the processing of precious metals, as it ensures minimal material loss while delivering high precision. Non-ferrous and colored metals can also be laser-cut, with the laser wavelength playing a crucial role in the process.

• Additive Manufacturing: In additive metal manufacturing, material is applied in the form of fine powder to create complex geometries and delicate structures. The process relies on an evenly distributed powder bed, achieving a material density of 99.9%. ALPHA LASER's 3D metal printers are already widely used in industries such as R&D, education, tool and mold making, jewelry, and medical technology.

How precise is the material buildup?

When repairing a turbine gearbox, we increase the diameter by 20 thousandths of an inch. The ALFlak 1200 proves to be a particularly precise tool, working with a flexible wire feeding system. This process allows for an exact material buildup and prevents oxidation through the use of a shielding gas method, such as with argon. As a result, the highest welding quality is achieved.

Stainless Steel Welding: Technologies, Equipment and Shielding Gases

Welding stainless steel requires a good understanding of the right welding technologies, suitable equipment, and the correct shielding gases. To maintain the material’s corrosion resistance, durability and clean surface finish, it is important to use processes that generate controlled heat and precision, such as TIG welding, MIG welding or laser welding. This guide shows how to weld stainless steel effectively and highlights what to consider during the process to preserve the material properties and achieve strong, long-lasting welds.

Soldering or Welding Copper?

Whether copper should be welded or soldered depends on the required durability of the joint and the thickness of the copper pipe or sheet. Soldering has a significant effect on the dimensional accuracy of the component, but soldered joints are less strong. For this reason, they are typically used where mechanical loads are low. Welded joints, on the other hand, are significantly stronger and more durable than soldered connections. For a robust and long-lasting joint, copper should therefore be welded.

Why is less material removal important?

A key advantage of laser welding compared to conventional methods such as TIG or MIG welding is the significantly reduced material removal. This not only saves time but also preserves the stability and integrity of the component. At the same time, the targeted use of less heat minimizes the risk of deformation or warping—an aspect that is particularly important for heat-sensitive parts. The low heat input makes post-treatment due to heat exposure unnecessary.

Aluminum Welding: The Risks

During aluminum welding, aluminum oxide particles may be inhaled, which can cause respiratory diseases and, in severe cases, aluminosis. In addition, ozone is generated during arc welding—a gas that can also lead to serious health risks. To protect against welding fumes, effective fume extraction systems must be installed directly at the welding point. Standard room ventilation systems are generally not sufficient to provide adequate protection. Wearing a welding helmet is also essential when welding aluminum and other materials.

Laser systems from ALPHA LASER feature two different laser sources used for welding aluminum:

• Pulsed Nd:YAG laser sources offer the advantage of high peak pulse power, which is necessary to penetrate the oxide layer. Laser systems with these sources are used for overlay welding with filler material.
   
• Fiber lasers (from 4 kW and above) in continuous wave (CW) mode, meaning non-pulsed laser welding, achieve high welding speeds and deep penetration. This type of laser source is used for fusion welding of aluminum without filler material. 

Remove the Oxide Layer Before Aluminum Welding

To prevent the aluminum from melting while breaking up the aluminum oxide layer, the oxide must first be removed when using conventional welding processes. The following steps explain how to remove the oxide layer before aluminum welding:

1. Preparation: Before the welding process, the workpiece should be thoroughly cleaned using a cloth soaked in acetone or butanol. Only once the metal surface is completely free of contaminants should the oxide layer be removed and the aluminum welded. If the surface is not properly cleaned, burn-in or contamination may occur, which can be difficult to remove later.
    
2. Removing the oxide layer (not required for laser welding): Aluminum oxide is best removed mechanically using a steel wire brush to break up the oxide layer. This step may need to be repeated several times, as aluminum oxidizes very quickly when exposed to air.

We are excited about the opportunities ahead and the positive impact we will make together. Welcome, Grupo COMAT, to the ALPHA LASER family!

Why Is Aluminum Difficult to Weld?

Welding aluminum is challenging because the material has several properties that make the welding process more complex compared to other metals, such as steel:

• Aluminum is soft: Aluminum is a relatively soft metal. As a result, it is prone to material distortion during welding due to heat input.
   
• Oxide layer: While welding metals such as steel is comparatively straightforward in terms of temperature control, aluminum presents a specific challenge. When exposed to ambient air, aluminum forms an aluminum oxide layer on its surface. This layer protects the material against weathering and corrosion. However, for aluminum welding, this oxide layer must first be broken or removed. The difficulty lies in the fact that aluminum oxide has a melting point of around 2,050 °C, whereas aluminum itself melts at approximately 660 °C. To prevent the base material from melting during welding, the oxide layer must therefore be removed prior to the welding process.

Both ALPHA LASER and Grupo COMAT share a commitment to continuous improvement and efficiency. We are dedicated to enhancing the capabilities and efficiency of businesses across Argentina with our innovative laser solutions. This collaboration will bring significant value to both our organizations and, most importantly, to our customers..

Advantages and Disadvantages of Welding Technologies at a Glance

The Partnership

At ALPHA LASER, we are committed to providing cutting-edge laser technology for a wide range of applications. Our partnership with Grupo COMAT will enable us to extend our reach and bring our state-of-the-art laser solutions to more customers in Argentina. Grupo COMAT’s strong expertise and dedication align perfectly with our mission to deliver high-quality products and exceptional customer service

How to Successfully Weld Aluminum

Aluminum Welding: Suitable Welding Processes

There are various welding processes available for joining metal components. The following welding technologies are particularly suitable for welding aluminum:

• MIG welding: MIG welding is a metal inert gas welding process that is especially suitable for thicker metal components, as the welding wire allows a higher deposition rate. Because filler material can be added very effectively when MIG welding aluminum, this method is particularly popular for fillet welds.
   
• TIG welding: TIG welding is also performed under a shielding gas atmosphere using a non-consumable tungsten electrode. It is especially well suited for thin aluminum sheets and fine structures that require precise control.
   
• Plasma welding: This welding process uses a plasma nozzle that surrounds the weld area, allowing the electrode to be precisely aligned with the weld seam. However, plasma welding is a complex technology and is therefore only rarely used for aluminum welding.
   
• Laser welding aluminum: Laser welding, or laser beam welding, is also suitable for professionally welding aluminum and other materials. Thanks to the use of fiber lasers and Nd:YAG lasers, ALPHA LASER welding systems achieve very high performance, including high peak pulse power and highly focused energy input. This enables precise and reliable welding processes. In addition, the low heat input during laser welding of aluminum significantly reduces material distortion.

Note: All welding processes involve a high risk of reflection for both operators and optical components.

About Grupo COMAT

Grupo COMAT is a distinguished company known for designing, producing, and integrating mechanical solutions that add significant value to their customers. They have a strong presence in the field of metalworking and industrial machinery and are highly regarded for their expertise in laser welding and cladding. Their commitment to meeting the requirements and expectations of their customers and other relevant parties sets them apart as a leader in their industry.

Grupo COMAT provides solutions for a wide range of industries, including automotive and auto parts, steelmaking, metal and foundry, the soap industry, sport and racing cars, agricultural machinery and tractors, home appliances, metal mechanics, heavy equipment, paper and cellulose, oil & gas and mining, plastic and rubber, refrigeration, food and beverages, robotics and electronics, seeds and oil refinery, as well as chemicals and petrochemicals.

Grupo COMAT strives to be a sustainable company, grounded in strong values and corporate social responsibility. They maintain high industrial performance standards and aim to build long-term relationships with clients, suppliers, and the community