The latest laser generation technologies are improving every day, and that’s making laser welding machines more popular and effective tools. But how does a laser welding machine work?
A laser welding machine, in its simplest form, uses a laser beam to join thermoplastics or metallic components. But laser welding can finish the job in a fraction of the time it takes with other traditional welding methods.
In this article, we will have an elaborate discussion about the welding process of these incredible machines. We will look at different types of laser welding methods and some generalized steps of the process. Keep reading to learn more.
What Is Laser Welding?
Laser welding is a very precise and surprisingly delicate way to join metal pieces together. It uses beams of light. A separate laser source sends the beam to a collimator “torch.” This torch can be attached to a machine or held in the hand and onto the workpiece.
The focused energy beam heats and melts the workpieces (and filler rod if needed). The melt pool that forms then joins the targets together, creating a strong weld.
The ability to expertly and closely control the applied energy is one of the best things about laser welding. The energy can be precisely directed to the spot where the weld is needed. Hence, it does not go too far or spread out.
This method of welding has a much smaller heat-affected zone than any other. Besides, it can liquefy very accurately. This hurts nearby areas less and lowers the amount of bulk heating and deformation that comes with it.
Laser welding is used a lot in the electronics manufacturing, aerospace, medical, and auto industries. It works especially well for joining materials like aluminum, which are hard to join using regular tools.
How Does a Laser Welding Machine Work?
A laser welding machine uses a concentrated beam of light to join metal pieces together. The laser beam melts the metal until it fuses with the other metal.
The principle that the laser beam generates heat is fundamental to laser welding. To simplify, a small area on the metal sheet can be heated to the melting point using a high-energy laser.
The physical and chemical properties of the material also determine which is the most suitable laser source. Common types of sources are gas lasers, fiber lasers, and solid-state lasers.
Besides, welding techniques might vary in their ability to regulate the depth of the hole.
The meeting point of the two metals or materials to be welded is where this procedure takes place. However, a laser welder can be used in various ways. The thickness, quality, and material being welded determine them.
Types of Laser Welding Methods
There are different types of laser welding procedures based on different methods and purposes. Let us talk about some of these laser welding methods to help you understand how they work.
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Heat Conduction Welding
In this process, the material’s surface is heated above its melting point using a laser beam. Because of this, this method is superior to others when a strong weld is not a top priority.
Heat conduction welding requires a laser that produces less than 500 W of power. The result is a straight and nice-looking weld.
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Keyhole Welding
Keyhole welding involves penetrating deeply into a material by heating its surface to the point of evaporation. A keyhole that mimics the appearance of plasma is created by this welding technique.
A laser with a power density greater than 105 W/mm2 is sufficient for this welding process. The temperature often goes above 17,500 degrees Fahrenheit.
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Hybrid Welding
The principles of laser beam welding and arc welding are combined in laser-hybrid welding. When you combine the benefits of both methods, this improves the quality and efficiency of the welding process.
The three main types of hybrid welding are TIG (tungsten inert gas), plasma arc, and MIG (metal inert gas) augmented laser welding. These are based on the type of arc used.
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Laser Brazing
Laser brazing is a heating method that has been used to join aluminum and steel. Within laser brazing, a filler metal is put on or between the framing surfaces of the metals that need to be joined. A laser beam is then used to heat and melt the filler metal, but not the parent metal.
With the help of capillary action, the liquid filler metal flows and fills the small space between the flaying surfaces. As the filler metal cools down and solidifies, it forms a joint with the parent materials by forming a diffusion bond at its edges.
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Percussion Welding
With percussion welding (PEW), different metals can be joined together using resistance welding. Percussion welding creates a high-temperature arc by means of a brief electrical discharge.
As soon as the electricity stops, pressure is put on the materials, which joins them together. As a result of this type of joining, the materials hit each other repeatedly.
Steps of the Laser Welding Process
In general, these steps make up the laser welding process:
- It is important to clean and align the parts that need to be welded. To get a better weld, the contact line should be closed and have no gaps.
- Maintain the stability of the parts while they are being welded with either manual clamps or automated fixtures.
- Point the beam’s focus on the area where you want to weld. The welding torch’s optical gear usually makes it easy to change the focus.
- Change the power of the beam and test it on scrap metal and test parts. Check that the machine is putting out enough energy to melt the material but not so much that it overheats other parts before moving on to the workpiece.
- Put the beam down at the beginning of the welding area. Once the right kind of melt pool has formed, it needs to be moved steadily along the weld. Using traditional welding methods, like hot point rotation, will help the weld fusion and make it better.
- In the end, let the part cool naturally after welding. You can also use water or other ways to cool it down.
Conclusion
A laser welding machine mainly works by generating a powerful beam with the help of a source. The beam is focused on the desired point to melt and create the weld. However, different types of welding methods can diversify the process.
One common laser source for the welding process is a fiber laser. However, to get the best-quality weld using a fiber laser machine, it requires the best machine. And you can get that quality from Fiber Laser Welder.
We are a top supplier of handheld laser welding machines that will transform your production processes. Our machinery, parts, and support are high-quality, efficient, and precise. Contact us today to get your desired machinery.
