A fiber laser welding system is a type of welding system that employs a laser beam to generate heat. Fiber lasers are inexpensive, low-maintenance, and quick welding instruments since they are non-contact. Because of its great precision and minimal heat input, the laser beam causes the least amount of material damage.
One growing application is connecting cylindrical and prismatic cells and modules to busbars. Continue reading to learn all the essential details and gain a solid understanding of the various options.
The Major Components of Fiber Laser Welding System
Fiber laser welding joins metals by using an extremely concentrated laser beam. A system of optical and electrical components produces the laser beam. These are the principal ones, along with definitions, in order of importance. Some of the significant elements of laser welding systems are given below.
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Power Supply
For usage by the pump source, the power supply transforms electrical current into direct current (DC).
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Laser Source
Parts of the laser source include the pump source, the gain medium, and the laser cavity. The electrical apparatus that transforms electrical energy into laser light is known as the pump source. Usually, it consists of a series of laser diodes. A rare-earth element-doped fiber (like ytterbium) serves as the gain medium. Excited molecules in the doped fiber produce light with a specific wavelength when pump light passes through it. The laser cavity amplifies that light.
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Fiber Optics Cable
The purpose of the fiber optic cable is to direct laser light and transfer it to the appropriate spot on the treated surface.
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Fiber Collimator
The collimator is a lens that changes the direction of the light coming from the fiber optic cable so that it can be more effectively focused.
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Beam Expender
The collimated laser beam becomes larger using the beam expander. The laser process tolerates surface and location fluctuations better in this method, but the beam is less focused.
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Scanning Head
The scanning head’s revolving galvo mirrors regulate the laser beam’s direction.
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Focusing Lens
The laser beam is focused on the surface that has been treated using the focusing lens. A 200 mm focusing lens, for instance, offers an excellent focus for welding at a 200 mm distance.
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Focus Shifter
The focus shifter is an optical assembly known as the 3D head. It may quickly change the focus distance to account for significant surface or positional fluctuations.
Other Components
In addition to optical and electrical components, fiber laser welding equipment has other parts. Some common ones are listed here.
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Wire Feeder
You can add filler material while welding by using a wire feeder. This method is a cross between laser and MIG welding. In some circumstances, wire feeding can aid in achieving excellent weld quality, but it slows down the welding process since more metal is melted by the laser’s energy.
When solidification happens too quickly, causing cracks, or when there are gaps in the joint fit, wire feeding can be helpful. It’s advantageous for modifying the weld’s mechanical properties as well.
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Shield Gas
Some manufacturers combine laser welding with a shield gas, like argon, to prevent the welds from oxidizing. However, using a shielding gas is not always necessary to obtain the desired weld quality. It’s always helpful because it lowers the amount of faults in the welds. Shield gas added later on will only help the process.
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Laser Controller
The controller is an electrical device that modifies the laser process by varying parameters such as pulse duration, repetition rate, and laser strength. Another purpose of the controller is to control safety features.
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Fume Extraction Unit
The work environment must be cleared of harmful gases and debris from laser welding. We offer advice on how to carry out fume extraction safely and efficiently.
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Laser Weld Monitor
Various LWM techniques are available to analyze the real-time welding process. Laser weld monitoring, or LWM, is necessary to guarantee good weld quality and identify any deviations from good weld characteristics. It also indicates when welds require rework (pass/fail).
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Chiller
Industrial welders that use high-power lasers must control the heat they produce to ensure a safe working temperature and avoid safety hazards. The utilization of various cooling methods, such as an air chiller or a water chiller, depends on the laser power.
Types of Fiber Laser Welding Systems
There are various laser welding methods, each with benefits, restrictions, functions, and uses. In this article, we’ll talk about many forms of laser welding. We’ll give a quick overview of each procedure and discuss how it differs from the others in laser welding.
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Handheld Laser Welding Machines
There are now more portable fiber laser welding machines available than ever before. Operators grip a “gun” to start and aim the laser beam, the same as in MIG and TIG welding systems. With such a minimal learning curve, even beginner welders can quickly pick up and produce high-quality welds.
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Laser Welding Workstations
Workstations are partially automated systems that usually need workers to load workpieces and start the laser welding procedure. They’re perfect for small-scale production runs. It also helps with product development and creating processes tailored to a particular use case. Our laser welding workstation for battery producers is an example of this.
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Robot Laser Welding Machines
The precision and repeatability of robot arms make them a popular choice for laser welding. It is possible to program robot arms to move the laser welding head across the workpiece precisely. This feature lets us weld big objects like pipes, car body parts, and aviation wings.
Benefits Of Fiber Laser Welding Over Traditional Methods
The market share of laser technology is growing daily as more sectors of the economy utilize this cutting-edge technology. Economic research claims that lasers are currently worth $11 billion to the manufacturing industry, and the number keeps getting higher. There is no coincidence here. These are a few advantages of laser welding that might help your company grow.
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Complex Welds
You can weld complex joints with a laser welding machine. Furthermore, this kind of welding is suitable for all welding positions. It works well for intricate prototypes as well. Unconventional designs are too complex for traditional welding to adapt swiftly. Lasers, on the other hand, can adapt swiftly with minimum changes.
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Material Versatility
The most significant advantage of laser technology is its broad spectrum of material compatibility. You may weld composites, organic materials, metals, non-metals, and thermoplastics with these machines. Moreover, it is possible to weld different materials together. This is a first for anything. Some materials are more suited for traditional processes than others.
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Accuracy and Precision
Lasers are unique because of their minuscule focus. One can use laser welding to target an area as small as 0.2 mm. In addition, laser welding requires the fewest tolerances compared to previous methods.
Laser welding also affects material thickness, making it simple to drill deep keyholes for neat welding joints. In addition, fiber lasers can easily weld at speeds of up to 16 mm/s, which was previously challenging.
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Vast Application
There are several uses for laser welding in the manufacturing sector. Few industries remain unaffected by the fantastic performance of laser technology as it continues to advance. Manufacturing appliances, automobiles, aircraft, oil and gas, and buildings are essential industries.
Spot and continuous welding are both appropriate uses for laser welding. Additionally, unlike the conventional procedure, spot welding does not require access to both sides of the material.
Conclusion
The fiber laser welding system is a revolutionary tool representing the perfect combination of efficiency and technology in manufacturing and precision assembly. Our mission at Fiber Laser Welder is to improve your manufacturing line by providing the best handheld laser welding machines available.
Our dedication to excellence, effectiveness, and accuracy guarantees that you receive machinery and a complete solution catered to your requirements. Improve your production skills with our exceptional assistance and knowledge.