Nowadays, experts in the field can be found using both laser welding systems and more traditional arc types of welding. Each version of the process is different in ways that make it useful in different situations. To better comprehend this, it’s a must to have proper knowledge of laser welding vs traditional welding.
Take this as an example: traditional welding lets less precise workpieces fit up. In contrast, laser welding can be done faster and with less chance of thermal distortion. Both sets of advantages play important roles in different applications. That’s why these welding techniques require comprehensive comparison.
In this article, we aim to give you a clear picture of the distinctions between laser and traditional welding methods. After learning about their benefits and applications, you will be able to select a welding method that meets your needs.
Laser Welding vs Traditional Welding: Key Differences
| Feature | Laser Welding | Traditional Welding |
| Heat-affected zone (HAZ) | Smaller HAZ caused by a focused laser beam on a small area | Larger HAZ resulting from heat applied over a wide area |
| Temperature input | Low temperature input due to smaller HAZ | High temperature input stemming from larger HAZ |
| Precision | High precision with a controlled and focused laser beam | Lower precision as heat is spread over a larger area |
| Thermal distortion | Low thermal distortion from low heat input and small HAZ | Higher thermal distortion from high heat input and large HAZ |
| Investment | High investment required | Low investment required |
Laser Welding Process
Laser welding technology uses a focused laser beam to join metals together. It can also be used to join thermoplastics. It is a type of fusion welding and is the most advanced way to weld. This method is used in a lot of different fields, from making fine jewelry to medical equipment and spacecraft.
When lasers are used to join two pieces of metal, a focused beam of light is sent through the space between them. A strong laser beam melts the seams between the materials and joins them together. A heat source that generates concentrated heat allows for ultrafast laser welding on thin metal sheets. Conversely, when welding thicker materials, lasers can make welds that are deep and narrow.
Advantages of Laser Welding
Laser welding has a number of advantages over conventional welding methods. Let’s go through them:
Less Heat
In contrast to traditional methods, laser welding necessitates a relatively low heat input. This is because the laser beam is very focused on a small area, which makes the heat-affected zone (HAZ) smaller.
Faster Processing Time
It is faster to use laser welding, which means more work can be done in less time. Even though it costs a lot to start, the process ends up being cheaper than traditional techniques.
Lower Risk of Thermal Distortion
The focused laser beam only melts a small portion of the metal’s surface. This keeps the workpiece from being too stressed and distorted inside from the heat. Since not much heat is added to the process, there is less thermal stress.
High Precision
Laser welding’s adjustable spot size makes it ideal for delicate or thin metals. This makes it possible to weld parts with great accuracy.
Laser Welding Application
We just talked about how laser welding offers many advantages in fabrication. Due to these perks, this welding method has found its place in various applications. Have a look at some of them:
- Laser welding works great for parts that control fluids and hydraulics because it is very accurate.
- Due to its pinpoint accuracy, this welding technique is ideal for thin shell assemblies that must remain distortion-free at all times.
- Welding with a laser beam is effective for producing foils and fuel rails, both of which require delicate handling.
- The medical field relies on using a laser welder for instruments owing to its clean and precise results.
- Using laser beams to melt metals allows for the efficient production of stainless steel heat exchangers and thin gauge metal boxes.
- Laser welding ensures consistency and reliability in the crafting of thin gauge parts and tubing.
Traditional Welding Process
Traditional welding involves arc heat melting the base metal and any necessary filler metal. The metals then fuse together as they cool. Shielding gas keeps the molten metal (the weld pool) safe from air pollution. Thus, the formation of a porous weld joint is averted.
There are a few types of traditional welding methods, including:
- Flux cored arc welding (FCAW): This method requires a flux-filled, continuously-fed tubular electrode and a constant-voltage or, less often, constant-current welding power supply.
- Shielded metal arc welding (SMAW): SMAW is a manual arc welding process that uses a consumable electrode covered in flux to lay the weld.
- Gas tungsten arc welding (GTAW or TIG): This type of arc welding utilizes a tungsten electrode. The electrode does not need to be replaced to heat the piece being welded and melt any filler that is there.
- Gas metal arc welding (GMAW or MIG): To make the weld, this arc welding method uses a consumable wire that is used only once. This wire acts as both the electrode and the filler material.
Advantages of Traditional Welding
The traditional welding process is still the gold standard in many manufacturing sectors. That’s because it has its own set of advantages, including:
Low Cost
Compared to laser welding, traditional welding requires less money to get started. As a result, traditional welding is a good option for fabrication jobs when money is tight.
Easy to Work
You can easily automate traditional welding processes. Manually mastering the method is also possible with enough knowledge and practice. Besides, traditional welding techniques are simple to grasp. That’s because they have been used for a long time.
Easy Implementation
Implementing the conventional welding process manually in an operation does not require sophisticated equipment.
Traditional Welding Application
As we said earlier, traditional welding includes a variety of processes. All of them are necessary for fabrication and manufacturing. Let’s look at some applications to better understand this:
- The traditional process of welding is widely used in shipbuilding to construct strong hulls and frameworks.
- In construction, welding is vital for creating durable steel structures and frameworks.
- The automotive industry uses welding to assemble car bodies and mechanical components.
- Aerospace applications demand precise welding for aircraft parts and pressure vessels.
- Railroads depend on welding for track maintenance and repair.
- Industrial piping and manufacturing plants utilize welding to assemble and maintain machinery and infrastructure.
- Autobody repair shops also use welding to fix and restore vehicle bodies.
Conclusion
Laser welding is a modern technique for joining thermoplastics and metals with a finely concentrated beam of light. Its benefits include reduced heat, reduced thermal stress, faster processing speed, and high precision. In contrast, conventional welding uses arc heat to melt the base and filler metals, which are then fused together once they cool. With traditional welding, you can save money and make things easier.
Although laser welding has a higher initial investment, the potential quality of the end product makes it worthwhile. However, a high-quality laser welder is required for a precise welding process. With the laser welding machines of Fiber Laser Welder, you’re guaranteed to get this quality. Contact us today to find the best services, parts, machines, and prices.
