10 Reasons to use Laser Welding

With numerous techniques available for joining materials, here are our top 10 reasons to choose laser welding.

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1. Laser welding works with a variety of materials

Laser welding is an effective method for joining an array of metals, including stainless steel, nickel, titanium, Inconel, and molybdenum. Importantly, it can also work with reflective materials, such as copper and aluminum, which are challenging for other welding techniques. For more detailed information, please refer to our Material Selection for Welding blog.

2. It can make microscopic welds

This method is utilized for welding medical device components, like microfluidic chips and surgical tools. If the components are small or in hard-to-reach areas, laser welding is the optimal choice.

3. It can also make big (deep) welds

Laser technology is not only adept at microscopic welding but also capable of creating structural welds that are 1/2" deep in thicker materials.

4. The process and results are highly repeatable

One of the significant advantages of laser welding is its repeatability. If you are pleased with the results of your laser welded components, you can expect the same high-quality output time after time.

5. Laser welding is precisely controllable

Each job can be customized in terms of laser welding parameters. The non-contact nature of this process allows for tight control over the size of the laser beam and the heat-affected zone.

6. Unmatched speed

Laser welding outpaces traditional methods like TIG welding, completing tasks in mere minutes that may take hours by other means, with travel rates reaching hundreds to thousands of inches per minute.

7. Need low heat input? Choose laser welding.

The thermal impact of laser welding is minimal, allowing for greater integrity of the materials being worked with, and reducing residual stress compared to other methods, such as MIG welding. This controlled heat affected zone ensures sensitive internal components remain undamaged.

8. Few size constraints on components

This technique can be applied in various environments, whether in an open space or a glovebox, making it ideal for larger components when the right laser is used.

9. Easily integrated with off-the-shelf motion products: CNC platforms, robots

Robotic technologies have increasingly incorporated welding, showcasing the continuous innovation in this field.

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10. Laser welding is cost effective

Among the numerous reasons to embrace laser welding, its cost-effectiveness stands out. This approach yields high-quality outcomes without straining the budget. Although the initial investment in laser welding technology may be significant, partnering with a contract manufacturer like Joining Technologies can make it economically viable.

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Navigating Laser Welding: Advantages and Challenges

Join us on THEO's blog for a deep dive into laser welding insights. Discover its advantages and navigate the challenges with expert commentary that provides a balanced perspective on its industry applications:

Laser welding has evolved tremendously over the past fifty years, including portable handheld welders gaining traction in the last five years. Notable early users of handheld technology included NASA for shuttle repairs. Indeed, this technology continues to play a pivotal role in various industries.

Advantages of laser welding and handheld laser welding

Lasers can focus light down to a microscopic spot, ensuring superior precision which is crucial for sectors like electronics and aerospace. The rapid nature of laser welding, being four to ten times quicker than conventional methods, lends itself well to high-demand environments.

High-Quality Welds Across Industries

With features like reduced splatter and porosity, laser welding is the preferred technique in industries where appearance and quality are paramount, such as automotive and food production.

Versatility and Minimal Heat Impact

This technique handles a wide range of metals, including both similar and dissimilar types, with minimal heat impact that preserves material integrity.

Reducing Material Distortion with Laser Welding

By creating a small heat-affected zone, laser welding minimizes distortion and is particularly useful for heat-sensitive materials.

Training and Automation: Streamlining Welding Processes

Learning to operate a handheld laser welder requires less time than traditional methodologies, making it accessible even to first-time users after a short training period. This technology integrates seamlessly into automated systems, promoting efficiency.

Disadvantages of Laser Welding

Navigating the Cost and Safety of Laser Welding

While lasers present many advantages, they also come with higher initial costs and necessary safety measures to protect users from laser hazards.

Equipment Size and Power Requirements

The size and power requirements may vary significantly between budget and professional units.

Conclusion: Weighing the Pros and Cons for Future Welding

Laser welding, while it may not yet suit every hobbyist due to cost, represents a transformative tool for production lines requiring high-quality, precise welding without significant material contact.

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