Types of Laser Welding: Ein detaillierter Leitfaden
Laser welding is a versatile process that caters to many applications. Every type of application has a different requirement for laser welding, hence various types of laser welding can be chosen.
If you are inclined to learn about laser welding and its types, you can read through this guide below.
What is Laser Welding and How Does it Work?
The significance of the laser welding process is very crucial in everyday life due to its versatile applications.
The method of laser welding consists of using a heat source which is a laser, and it leads to melting material. The process of laser welding is applied over different types of materials and may help the manufacturing industry to produce laser-welded parts quickly.
When compared to the traditional methods of welding, laser welding is a quick process and it costs much lower. Therefore, when producing a high volume of components, this process may take less time.
7 Different Types of Laser Welding
There are 7 different types of laser welding, which are given below:
Fiber Laser Welding
Fiber laser welding uses focused beams of fiber laser, which act as an energy source. The concentrated beam helps melt the Material and join the pieces together, creating strong welds.
This process uses diode lasers which produce light emission, and the wavelength of the laser is manipulated to suit the application requirement. The weld created by fiber laser is always strong, and the speed of joining is fast, with high control over the process. Fiber laser welding is suitable for fusing materials that are delicate and thin.
Keyhole Laser Welding
Keyhole welding is a very advanced method that can create a deep and narrow hole in the component during the welding process. The keyhole welding process uses a high-powered laser beam that can create a keyhole.
The material in this process is vaporized, and due to the vapor pressure, the keyhole remains stable. It is suitable for thick materials and ensures fully penetrated weld, creating high quality and less distorted welds.
Conduction Welding
The conduction laser welding process is the one in which the heat conduction leads to the joining of metal pieces. The process of conduction welding is suitable for materials that are thin and have low heat conductivity.
The laser beam, when passed through the components at the joining point, fuses the material by absorbing the energy and melting the material. This process uses low-powered lasers and offers controlled heat conduction for joining the welds. It is suitable when joining delicate materials.
Deep Penetration Welding
The process of deep penetration welding uses laser beams with high power, so that the components can be welded in depth. Since this type of laser offers a high beam of energy, it welds thick materials.
A focused beam of laser offers to create welds with high beams that are deep and a cavity is formed in the workpiece. Deep penetration welding can weld thick materials very quickly and also is suitable for applications that want to avoid multiple welds.
YAG Laser Welding -Neodymium-doped Yttrium Aluminum Garnet
YAG laser welding uses solid-state lasers, which are neodymium-doped yttrium aluminum garnet lasers. These lasers offer versatility in welding as they use laser beams equipped with high energy.
As soon as the laser beam reaches the workpiece, it leads to the melting of the material due to heat and creates a weld pool. After solidification, a very strong weld is created.
Laser-Hybrid Welding
Laser hybrid welding is a very advanced welding method that uses a combination of laser and arc welding. It can create highly precise welds for metal components. During this process, the laser beam allows the materials to weld. The arc welding offers filler materials, creating heat in the welding zone.
The combination of arc and laser welding offers the creation of deep welds at a quick speed, and even there is better control leading to reduced distortion.
CO2 Laser Welding
CO2 laser welding uses the carbon dioxide laser beam which helps in joining metals. It is a very practical welding technique in which gasses like helium, carbon dioxide, and nitrogen are used to create a heat source that melts the material and welds it together.
It is suitable for welding delicate and thin materials and also offers precise control during the process.
The Advantages and Disadvantages of Laser Welding
Some of the advantages of laser welding are the following:
- Laser welding is a precision-oriented process that helps to create small welds equipped with accuracy as the beam energy is controllable.
- The process of laser welding offers quick welds, it can quickly heat the material making the weld pool, and also, the solidification process is very quick.
- Laser welding is suitable for joining a wide range of materials, including plastics, metals, and even ceramics. Materials that are not identical can also be joined using laser welding.
- Laser welding ensures high-quality welds, these welds do not have any fractures, porosity, or defects.
- Laser welding is an ease-oriented process that also offers automation, hence consistent and high volume of welded components can be achieved through this process.
Some of the limitations of laser welding include the following:
- Laser welding equipment is very costly when compared to traditional welding machines.
- Laser welding requires very careful management as it may be hazardous and safety practices are a must.
- Laser welding is capable of welding multiple materials, but still, some of these may not be welded due to their chemical and thermal properties using laser welding.
- Laser welding goes well with applications that require welding materials that are light and thin and are suitable for heavy-duty components.
- The laser welding equipment requires maintenance, which leads to increased operational costs.
How to Choose the Right Laser Welding Method?
Among the different laser welding methods when it comes to choosing one, some of the aspects to consider are given below:
Compatibility of Material
There are different types of materials that can be welded with one another to form a particular component. Every material has different properties and thicknesses. Hence, when it comes to choosing the right laser type, you must assess the material of the component. Every type of laser welding may not suit every type of material.
Nature of Joint
The configuration of joints is also a matter to consider when choosing the laser welding type. Some laser welding types are suitable for certain welds, and some are not.
Speed of Welding
The availability of time and the volume of components that are to be welded are also considerations when choosing the type of laser welding. Some types of laser welding methods help produce a high volume of components in less lead time, and some don't. So, according to your volume and timelines, you can choose the laser welding method.
Heat Impact
When the process of welding is done, the surrounding area of the material is also considerable. Some methods of laser welding produce less heat, and some produce more. Hence, if the surrounding material is not heat resistant and the welding technique produces heat, the impact on that component would be a problem.
Budget of the Project
Laser welding is a costly process, and based on your budget, you have to assess which type of laser welding may be suitable and affordable. Diode laser welding is usually the more affordable solution compared to others, but you have to consider other aspects of the component.
Applications of Laser Welding Technology
Laser welding technology is quite popular in a lot of applications. Some of these laser welding applications are the following:
Medizinische Industrie
There are various pieces of equipment used in the medical industry which include surgical blades, medical implants, and many more. Laser welding projects are a better choice for welding these tools as they offer high precision. In the medical industry, YAG laser welding is mostly opted for as it offers suitability for welding delicate and thin materials.
Autoindustrie
The automobile industry has versatile components that need precise and high-quality welds and laser welding is therefore commonly opted for. Components like fuel injectors, engine parts, and filters are mostly welded using laser welding methods of different types.
Luft- und Raumfahrtindustrie
In the aerospace industry, laser welding is opted for welding components that require accuracy and precision. The components manufactured using other welding techniques in aerospace include airframes, metal detectors, and many more. The aircraft components need to be durable and the laser welding technique offers strong welds suitable for pressure-oriented conditions.
Schlussfolgerung
Laser welding is an innovative joining method that offers a lot of benefits compared to traditional methods.
If you are looking forward to getting laser welding carried out for your components, you can get in touch with us at DEK. We offer high-quality welds using multiple laser welding methods.
