Among various welding processes that exist, laser welding has emerged as a highly efficient process favored in modern industries. This welding technique uses the energy of a laser beam to heat up and eventually melt material at a certain spot for fusing objects together. Owing to its precision and efficiency, laser welding has gained a significant place in multiple industrial applications.
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Unlike some traditional thermal welding methods, laser welding induces less thermal damage to the material around the weld, resulting in high-quality products. Moreover, it allows for a wide range of materials, including those with high melting point, to be welded with precision and speed.
No, an electron beam is generated through an electron beam gun which accelerates electrons onto the workpiece. The kinetic energy then causes the parent materials to melt and fuse.
A laser beam is generated by rapidly raising and lowering the energy state of an &#;optical gain material,&#; such as a gas or a crystal, which causes the emission of photons.
The photons are subsequently concentrated and made coherent (lined up in phase with each other) and then projected on the surface of a part where radiant heat &#;couples&#; with the material, causing it to melt and produce the weld. Unfortunately, the majority of the laser&#;s power is wasted on heat and reflected off the part&#;s surface. Thus, by contrast, the depth penetration per unit of power in a laser weld is less than that of an electron beam weld. This problem can be mitigated by pulsing the laser, i.e., varying the power of the laser during the weld cycle. Pulsing the laser lowers the average power during the weld cycle keeping the part relatively cool. This can be particularly beneficial in achieving a strong weld on highly reflective materials such as copper and aluminum.
For the right applications, laser welding can be as strong or stronger than MIG welding. Laser welding doesn&#;t need filler material which increases the strength of the welds. The laser&#;s ability to deeply penetrate into materials results in purer, stronger welds than traditional welding techniques. Not only is laser welding typically stronger than MIG, it&#;s three to ten times faster, welding relatively thick joints with ease, all without requiring multiple passes or high heat, which can diminish the strength of the welded materials.
There are some applications where laser welding can replace MIG welding. That&#;s not to say that every MIG welding job can be laser welded or vice versa. Each application is different and needs to be reviewed by a skilled engineer before deciding.
This answer changes by the application. There are situations where laser welding would lead to a stronger part than TIG welding but the reverse can be true in certain applications. Contact an engineer for help determining the best welding application for your project.
Laser welding isn&#;t great for welding highly reflective materials like copper and aluminum. This is because most of the energy applied to the part is reflected off the surface.
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Laser welding also isn&#;t great for some dissimilar metal combinations. EB Industries has invested in proprietary technology that allows us to weld dissimilar metals and difficult to weld materials.
Laser welding can&#;t achieve the same depth of penetration as a process like electron beam welding due to the reflectivity. Technology is expanding to improve this but it&#;s not at the same level as other welding methods yet.
Laser welding can achieve a penetration of up to 1 inch in steel.
Yes, laser welders use a shielding gas to protect the weld pool from outside contaminants as well as air particles. Argon is a common shielding gas used in laser welding.
On some occasions they can but, the majority of the time, laser welding is done without the use of filler material or wire. This leads to a higher purity of the weld due to only having the parent materials melt and fuse.
No, laser welding doesn&#;t require filler material. Some material combinations like Aluminum to itself require the use of filler material but filler material isn&#;t required for a large majority of welding applications.
Yes, there are some applications with tricky joint designs and configurations that require laser welding to be done by hand. This can be done in several ways but most commonly is done using smaller low powered laser systems. Handheld laser welding is an ongoing development technology that has gained traction over the last few years.
Laser welding tends to be a cheaper process than alternative joining methods like electron beam welding. This is because laser welding can be done in open air and is a quick and highly repeatable process once programmed and developed. There can be situations where laser welding would be a more expensive joining method but, for the most part, it&#;s cheaper than other welding methods.
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