How Efficient and High-Quality Is Laser Welding Compared to Traditional Welding Methods?
In comparison to traditional welding methods, laser welding is much more efficient and the output is of a much higher quality. Laser welding functions as a beam of light that provides a concentrated heat source to melt materials, which then fuse upon cooling. Therefore, the application of laser welding requires less heat than conventional welding methods as the heat-affected zone (HAZ) is much smaller and more concentrated. As there is less heat required, this also translates to a lower risk of distortions and deflections in the final output, making it much higher quality. The processing speed of laser welding is much greater than traditional welding methods, making it far more efficient.
Can Laser Welding Be Used To Weld Dissimilar Metals?
Yes, laser welding can be used to weld dissimilar metals such as: brass-copper, copper-nickel, low-carbon steel-copper, nickel-titanium, titanium-aluminum, copper-titanium, and titanium-molybdenum. It can be challenging to form a true metallurgical bond at the weld seam for dissimilar metals, however, this can be overcome by creating a mechanical “entanglement.” This is a combination of dissimilar metals to ensure they are physically held together with enough mechanical strength to ensure a connection and can be achieved by physically pressing together the two metals and using a series of laser pulses to forge them both together locally.
How Efficient and High-Quality Is Laser Welding
Can Laser Welding Be Used To Weld Non-Metallic Materials?
Yes, laser welding can be used to weld composite materials, glass, and in some cases, ceramics. Welding ceramics can be more complex—the materials must not crack under the high temperature of the laser beam. To mitigate this, preheating is necessary to roughly 1,500 degrees Celsius and must be performed in the air.
What Are the Advantages of the Application of Laser Welding?
The accuracy and precision of the laser welding machine is the most significant advantage of its application. The depth and speed of welds created by the laser’s extremely powerful and focused beam of light enable a high volume of production that is extremely efficient. The restricted heat, minimal distortion, and precision with which lasers can join multiple pieces of metal together make it a highly desirable and effective method of manufacturing. Laser welding can operate at room temperature, or take place under special conditions such as within a vacuum or some gas environments. Finally, it can be safer for workers than other methods of welding in circumstances when the laser beam can be operated from a distance.
What Are the Disadvantages of the Application of Laser Welding?
Laser welding requires highly skilled operators to use the machine due to the high precision with which the laser beam works. Once the laser is focused, the spot size is incredibly small and the weld is narrow, therefore initial beam positioning is crucial to ensure accuracy. Handlers of the laser welding machine must therefore be highly trained. Another disadvantage is the expensive initial capital investment in acquiring the machine. Furthermore, there is a high cost of training the operators to a level at which they can safely and correctly use the laser welding machine. One final disadvantage of the application of laser welding is the potential health risks associated with it. The intense heat and light generated by the lasers pose a risk of burns and damage to eyesight if adequate precautions are not taken, and the fumes produced can be harmful if inhaled.
How Efficient and High-Quality Is Laser Welding
What Are Some Challenges in the Application of Laser Welding in the Manufacturing Industry?
The laser welding machine produces the beam for the welding process and requires a high-voltage power supply to operate. Shielding gas can sometimes be used to prevent any contamination from being released into the atmosphere. One of the challenges with laser welding machinery is the high capital and maintenance costs. On the other hand, this challenge can be balanced out by the decreased post-weld processing costs—as laser welds are so clean, they require no subsequent grinding. Another challenge is that the energy conversion efficiency is much lower than expected, roughly 10%. Additionally, whilst the precision of the laser beam is an advantage to many forms of manufacturing, it can be challenging to maintain 100% accuracy at all times, meaning there is a low gap tolerance. If the end product doesn’t meet the high-precision threshold expected of laser welding, this can lead to waste. However, this can be mitigated by ensuring operators have undergone the correct training and have the right skill set to manage the laser welding machine.
What Is the Difference Between Laser Welding and TIG Welding?
Laser welding has a much lower contamination risk than TIG welding and is therefore much more commonly used in the manufacturing of equipment such as medical instruments. The higher precision of a laser beam makes it much more accurate to create smaller and finer detailed apparatus. Laser welding enables the bonding of much thinner materials and greater tensile and bending strength. Unlike laser welding, arc welding requires filler or bonding material to join two pieces of metal. Laser welding simply creates a direct bond between metals, leaving no excess filler behind.
