Laser Welding

What is Laser Welding

Laser welding (LBW) is a process that uses lasers to melt material on the surface of workpieces, allowing them to be joined together with another piece made from similar material. This technique is commonly applied to metals or thermoplastics. Different types of lasers, including solid-state or gas lasers, are employed in laser welding applications today.

With their high power density, lasers are capable of precisely melting the material of workpieces. This occurs when molecules near the surface are subjected to a powerful laser beam, causing them to become excited and take on fluid-like characteristics. When excited molecules of similar material meet each other and transition down excitation states simultaneously, solid structures reform and molecular bonds form on a molecular level. This process enables pinpoint precision and reliable results.

Where is Laser Welding Used?

With the high power density of lasers, materials in workpieces can be melted in a controlled and orderly manner. By subjecting the surface to an intense laser beam, the molecules receive enough energy to become excited and take on fluid-like properties. Excited molecules of the same material can then collide and switch back to lower excitation states, forming solid bonds and solidifying at the molecular level. This process is highly effective and offers precise results.

Advantages of laser welding

High-speed laser welding offers several benefits, including:

■High-precision accuracy, even for small parts

■Low heat input, resulting in minimal distortion

■Non-contact welding, which prevents degradation in welding quality

■No current passing through the part

■Ability to weld dissimilar metals, such as Cu to Al

■Minimal maintenance required, ensuring high tool availability

■High productivity and yield, thanks to easy automation

■Overall, high-speed laser welding provides a cost-effective solution, with high part yields at low operating costs, resulting in the lowest cost-per-part.

Discover the versatility of lasers 3

Laser welding is a standout technology in modern manufacturing, thanks to its incredible versatility. With its flexibility for joint geometry, laser welding is the ideal choice for industries producing a range of products. Moreover, it is more energy-efficient, faster, and more precise than traditional welding methods. In fact, modern welding machines even operate automatically, providing another key element of modern production. Laser welding is undoubtedly the way to go for any industry looking to keep up with the demands of modern manufacturing.

Welding copper

Copper components are crucial in numerous industries, ranging from e-mobility and electronics to jewelry and watchmaking. When it comes to welding this shiny material, two major obstacles arise: creating consistent high-quality weld seams and minimizing spatter. Fortunately, laser welding is the ideal solution. Achieving robust connections with high conductivity levels, reproducibility, and no contact is critical.

Laser plastic welding

Laser-based plastic joining boasts numerous advantages that surpass those of traditional processes in multiple industries, such as adhesive bonding and ultrasound or vibration welding. The process includes four types of laser welding that are specifically used for joining plastics: contour welding, quasi-simultaneous welding, simultaneous welding, and mask welding - with approximately 300W laser powers frequently utilized during plastic welding operations.

Soldering

Soldering is a method used to join two parts together using a material called solder. The filler material melts at a lower temperature than the components being joined, so only the solder is melted during the process, leaving the other pieces unaffected. Once the solder is molten, it flows between the components and adheres to the workpiece surfaces, forming a diffusion bond. This internal capillary effect allows the solder to reach the joints more efficiently. Soldering is a highly effective way to join parts and can be relied upon for strong, durable connections.

Deep penetration welding

Deep penetration welding demands extremely high power densities, roughly 1 megawatt per square centimeter, as its process utilizes laser beams that not only melt metal, but also generate vapor.

Heat conduction welding

Heat conduction welding utilizes laser beams to expertly dissolve two parts and form a weld that is structurally sound. This method is frequently used to join thin-wall parts, and is highly effective in creating durable bonds along edges or joints.

Hybrid welding

Through the integration of laser welding with other welding processes, we can achieve unique applications in steel construction.

Scanner welding

Scanner welding provides extremely productive and versatile system concepts that enable faster, more precise, and cost-effective welding production compared to conventional welding processes.

Deposition welding

Deposition welding is a highly effective process used for surface finishing and repairing or modifying existing components. Whether through manual or automated laser deposition welding techniques, we can confidently achieve the task at hand with precision and accuracy.

Spot welding and seam welding with lasers

Laser welding is a versatile technology that can be used for both spot welds and continuous wave mode welding. The geometry of the weld refers to how the parts fit together, for example, whether they overlap or butt up against each other. When deciding between continuous welds and individual welding spots, or spot welds, you should also consider whether the heat input into the components exceeds the strength requirements for individual spots or spots welded simultaneously, versus small circles that connect them. All of these factors are important in determining the most suitable type of weld based on two key criteria: the required strength and the maximum heat input into the components. Overall, laser welding provides a reliable and effective solution for a wide range of welding needs.

Examples of laser welding applications

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