6 Disadvantages of Laser Welding

Laser welding is an up-to-date joining procedure known for accuracy and speed. However, it comes with some particular drawbacks regarding cost, safety, and usability. This article will take you through the disadvantages of laser welding to know the limits, challenges, and where this welding method may not be effective.

What is Laser Welding?

Laser welding is a method that uses focused light energy to melt and join materials. Welds are clean, very narrow, with minimum distortion, making this suitable for those industries that demand high accuracy.

The process is non-contact, in which the laser beam transfers energy without direct touch with the workpiece and, therefore, permits much speedier welding than any conventional method for its application in magnetic and non-magnetic materials, automotive, electronics, and aerospace, indeed, even medical equipment manufacturing.

How Does Laser Welding Work?

A laser beam illuminates a joint focused over the area, developing excellent heat. The material finally undergoes melting and subsequently gets fixedly joined after cooling.

You may choose one out of the following modes:

Conduction Mode Welding: Energy absorption occurs at the surface. Thus, shallow welds are formed. This is best for thin sheets.

Keyhole Mode Welding: The laser penetrates deeper, producing narrow but high-strength welds. This mode is applied when medium-thick parts are to be welded.

Such selection would depend on the design requirements of the element, the type of material, and the accessibility of the joint.

6 Disadvantages of Laser Welding

High Cost

Laser welding frameworks are costly and valuable. You need to invest in lasers, optics, cooling systems, and automation tools.

Maintenance is a separate hidden expense. The optics need cleaning and alignment, and laser sources degrade over time.

You must also hire experienced technicians who understand how to control beam power, focus, and speed. If you are a small or medium-sized operator, these high initial and running costs simply do not justify themselves.

Limited Penetration Depth

Laser welding is an excellent joining technique for thin sheets and medium-thickness components. However, it suffers drawbacks when it comes to very thick sections; although the energy density is high, in some cases, the beam does not penetrate deeply enough.

• Welding a 1mm stainless steel sheet is easy and quick.
• A 25mm thick steel plate requires multiple passes, hybrid welding, or entirely different methods.

Thus, it is also not suitable for shipbuilding or structural steel fabrication.

Sensitivity To Materials

Not all materials behave well with laser welding. For example, reflective metals such as copper and aluminum overcome the beam and result in poor absorption.

You may face:

• Inconsistent weld penetration.
• High porosity and cracks.
• Unstable keyhole formation.

Specific pulsed lasers or fiber lasers may mitigate this, but these further add to the cost. Therefore, if you are holding production for these grades, laser welding may not be a practical solution.

Safety

The high-intensity beam of a laser is dangerous. Direct or indirect contact can cause permanent damage to the eyes and result in burns on the skin.

You must follow strict safety measures:

• Workstations enclosed.
• Protective glasses for specific laser ratings are required.
• Ventilation for fumes to be removed.
• Safety connections to prevent accidental exposure.

The use of laser welding machines without the measures mentioned above exposes workers to considerable danger, which justifies additional cost for agreement and training.

Limited Joint Access

The laser beam requires a direct line of sight. When the weld joint is restricted or has a complicated configuration, positioning becomes difficult.

For example:

• Welding inside a closed tube is almost impossible.
• Welding joints at multiple angles requires expensive robotic systems.

If the design needs difficult areas to access, other welding processes like TIG or MIG are more flexible.

Reduced Weld Strength

Under specific conditions, laser welds may not reach the strength of conventional welds. A joint can be reduced by shallow penetration or gaps, or cracks. This is often observed in cases of different welding.

Thus, material compatibility must be evaluated before laser welding is relied upon for structural parts.

How Does Material Thickness Limit Laser Welding?

The direct effect of the material thickness on the penetration and the quality of welding. Whether it attaches well while it is below 6mm thick. When we increase the thickness, the laser energy will be spread out without reaching the bottom of the joint.

This leads to:

• Incomplete fusion.
• Cracks at cool down.
• Poor strength in the flexible failure of welds.

The restriction of laser welding on thick material delivers hybrid welding (laser + arc) or multiple passes, which add to both cost and time experienced.

What Makes Laser Welding Expensive?

There are three main reasons why laser welding costs:

Equipment: The dollars for lasers, mirrors, optics, and cooling systems.

Maintenance: Needs regular maintenance, and frequent measurements-the parts get reduced too fast.

Skilled Labor: The activities have a specialized training program to deal with the beam properties required for the prevention of defects.

Although the process saves time per weld, low investment in production volume may not be justified.

Which Industries Should Avoid Laser Welding?

Not all industries are associated with laser welding. It is best avoided if:

• You work with really heavy materials, demanding intense welds.
• Your design involves hidden joints or an even more complex configuration.
• You have a tight budget under which you work, where price is very much critical.
• You require a weld to be done on highly reflective metals most of the time.

In those situations, arc welding or even resistance welding might work better and be more efficient.

DEK’s High Quality Laser Welding Services

DEK does not just provide laser welding services but rather develops solutions that highlight accuracy, safety, and cost-effectiveness. Our professionals study your project requirements, analyze the challenges, and design welding approaches that confirm expected results.

Whether you are manufacturing sensitive electronic components, constructing complex medical devices, or producing tough automotive parts, consistency is guaranteed by our team. With our state-of-the-art facilities and experienced engineers, DEK provides modified welding solutions that improve product quality and reduce risks occurring from manufacturing issues.

Contact us today and get a free quote.

Conclusion

With an understanding of laser welding disadvantages, you may better evaluate whether this process fits into your industry. While laser welding affords accuracy with small deformation in high-speed operations, cost and safety issues must be considered.

Since the most suitable joining method depends on your material type, thickness, and project specifications, DEK is there to assist you with every type of application, from confirming reliable results to achieving lasting performance.