Have you ever been curious about how metals combine so well? A filler metal is introduced to a junction during the welding, brazing, or soldering process in metalworking for a successful and longer-lasting fusion. With many types of welding processes available, today, we will be talking about laser welding filler material. We’ll go into the fundamentals of laser welding as well as the essential function of filler materials to reveal the secret to forging enduring connections. Let’s start!
Choosing Between Powder And Wire Filler Material
You can use wire or powder to provide more material to the connection while utilizing a laser to weld. However, wire is used in the majority of enterprises. This article will discuss welding wire utilizing a fiber laser. The preference for wire is primarily due to its lower cost. In general, wire is less expensive than powder. For instance, a pound of 0.9 millimeter-thick Inconel 625 wire may cost about $26. However, it may cost you roughly $48 if you want the same amount of powder for the same material. For this reason, powder is mainly used in additive manufacturing applications rather than welding.
When Is Filler Wire Necessary In Laser Welding?
After studying different laser welding techniques, it’s been proven that, in many cases, the use of welding wire is essential to successful laser welding. Because of its accuracy and control, laser welding can occasionally be done without the need for welding wire. However, there are other situations where employing welding wire is preferable. Various factors affect whether filler wire is necessary for laser welding. Let’s have a look at them:
Material Type
The type of material you are welding dramatically impacts whether or not you need welding wire. For example, you may not require a lot of welding wire when joining two separate stainless steel components since these materials melt at roughly the same temperature. However, welding wire can strengthen the joint and fill in gaps when joining materials that melt at very different temperatures, ensuring that the weld remains balanced and robust. For example, when attaching aluminum to steel, you would use a specific type of welding wire that suits both materials.
Gap Bridging
Although laser welding is extremely accurate, it may have trouble joining materials if there is a large space between them. Thus, welding wire can be used to overcome this problem. This wire creates a solid connection by bridging the distance.
Joint Strength
Welding wire is a tool that is sometimes used to improve the quality of the weld while creating intricate joins or unique components. Particularly for challenging tasks, this welding wire can contribute more material to the weld, increasing and extending its durability.
Accuracy Requirements
Filler wire may help control the melted metal better, particularly in cases when precise welding is crucial.
Process Efficiency
Adding filler wire enhances the speed of laser welding, which is already quick. The process goes more quickly and smoothly because it keeps the welds solid and constant.
Material Thickness
The thickness of the materials is crucial during laser welding. If they are thin, you may combine them without additional wire because less heat is required. However, welding wire ensures that the weld is robust and correctly linked if the materials are thick.
Specific Applications
The job requirements will determine if a welding wire is needed while using a laser. Wire welding may be the best option if the object to be welded needs to be highly durable, resistant to rust, or entirely sealed. Welding wire can ensure high-quality welds on jobs where quality is crucial. However, there are situations where welding wire might not even be necessary if saving money and quickness are more critical.
Laser Welding Filler Material: How to Choose the Right One for Your Machine
Thanks to laser welding, the ability to weld with greater precision and a wider range of alternatives has revolutionized. Welding wire only adds more to the outcome. That’s why selecting the proper welding wire is crucial since it allows us to weld more effectively and quickly. Let’s look at the factors that can impact your choice of the right filler material.
Handheld Laser Welder
There are two primary types of wire to choose from when selecting one for a handheld fiber laser welder. One is stainless steel wire, which is fantastic as it is compatible with most metals—aside from aluminum. It is, therefore, a good option for welding various materials. And then there’s aluminum wire, specifically designed for aluminum work. Therefore, the one you choose will rely on the materials you’re welding and the requirements for your portable fiber laser welding project.
Material Compatibility
The most crucial consideration to make first is whether the welding wire is compatible with the materials you are using, whether it is stainless steel, aluminum, or another metal. Using the appropriate filler wire can help ensure that your weld is strong and long-lasting. That’s because different materials have different qualities when they heat up and change shape.
Wire Diameter
When you weld something, the size of the welding wire also proves to be critical to think about. The size modifies the amount of heat to be applied, the size of the metal to be melted, and the weld’s quality. Bulky wire works best when filling large holes or welding bulky objects. However, thinner wire is preferable if you are looking to perform precise work.
Composition and Alloying Elements
Understanding the contents of the welding wire you’re using is crucial. The materials used in the wire can significantly alter the weld’s strength, corrosion resistance, and elasticity. Use a welding wire with chemicals to improve the quality of the material you are welding.
Surface Finish and Cleanliness
The external appearance of the welding wire can impact the quality of the final weld and the effectiveness of the welding process. The clean and well-coated wire helps keep out chemicals and facilitates feeding the wire into the welding area. To ensure your weld goes smoothly and without issues, look for cables with a smooth, flat surface.
Process Compatibility
Consider whether you are applying an autogenous (autonomous) or filler wire-added laser welding process. Select a wire based on the sort of welding you’re doing and the equipment you have. Not all cables are compatible with all types of welding.
Welding Environment
The type of wire you use will depend on the space where you will perform the welding task and the surrounding environment. It’s because factors like temperature, humidity, and airborne particles can all affect the situation.
Regulatory Compliance
Verify that the welding wire you choose complies with industry regulations and requirements. This is critical in businesses with stringent quality and safety regulations, such as the nuclear, automobile, and aerospace sectors.
Advantages And Disadvantages of Using Filler Wire in Laser Welding
Precision and accuracy have always been key considerations in laser welding and that’s why it’s a delicate task. Incorporating filler with laser welding brings significant benefits but there are drawbacks, too. Let’s take a look!
Advantages
- Welding wire improves the quality of welds by sealing gaps, correctly attaching components, and ensuring no errors exist. Additionally, it strengthens the weld, which is crucial for demanding tasks.
- One of the most crucial things that welding wire aids with is heat management.
- Filler wire can occasionally speed up processes.
- Welding wire is used to fill in the spaces left by misaligned parts, allowing the pieces to be still welded together.
- The proper type of welding wire ensures that the components function as a whole. It expands your welding capabilities by enabling you to weld components of varying thicknesses and materials together.
- Additionally, welding wire gives the welder greater control over their work, helping them achieve accurate outcomes.
Disadvantages
- Filler wire is not necessary for all materials. However, when it is required, choosing the wrong filler wire and base material may result in disaster.
- Welding can become more complex when filler wire is used. It entails managing the filler material and feeding the wire using devices. This increases the difficulty and skill level of welding.
- Welding might become more expensive when filler wire and equipment are used. Therefore, it’s critical to consider whether the additional expense is justified.
- Using welding wire can result in additional waste, mainly if the wire is left behind after welding.
- The welder’s skill level and parameters, particularly when employing filler wire, determine the quality of the weld. That’s why it’s extremely important to ensure that the right man is doing the right job!
Summing Up
Laser welding filler material is an important subject in precision welding. We at Fiber Laser Welder know how important filler material is in getting flawless welds, as we have a lot of experts in the field. Due to client demand and our continuous dedication to quality, we searched worldwide for the greatest technology. By providing portable laser welding machines that improve the manufacturing process, we continue to be at the top of innovative ideas. We deliver excellent quality, accuracy, and efficiency, resulting in welding projects that are like works of art. Contact us today!
