What is fiber laser welding machine and Why Do We Use Them?

Fiber laser welding is a welding process that uses a laser beam as the heat source. As non-contact tools, fiber lasers are low maintenance and offer fast welding speeds. The laser beam is highly precise and has a low heat input, which minimizes damage to the material.

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One of the emerging applications is to make cell-to-busbar connections for cylindrical and prismatic cells and modules. You can see an example in the following video:

To get a good understanding of the different possibilities, continue reading to discover all the essential information.

• Benefits & Challenges
• Fiber Laser Welding Systems
  • Optical & Electrical Components
  • Other Components
  • Continuous vs. Pulsed
  • Single mode vs. Multimode
• Types of Fiber Laser Welding Systems
  • Handheld Laser Welding Machines
  • Laser Welding Workstations
  • Robot Laser Welding Machines
  • Robot-Assisted Laser Welding Machines
• Fiber Laser Welding vs. Other Welding Methods
  • Laser vs. Ultrasonic Bonding
  • Laser vs. MIG Welding
  • Laser vs. TIG Welding
  • Laser vs. Resistance Welding
• Laser Welding Applications

Benefits and Challenges

Fiber laser welding is becoming increasingly popular in manufacturing to scale up production and improve quality. But it also comes with its own set of challenges presented below.

Benefits Challenges The welding speed is fast and can be scaled to each application by adjusting the laser power Weld quality is affected by external factors (such as joint gap, material defects, etc.) The process is precise and easy to control, making it highly repeatable Laser safety measures are needed to protect workers and the work environment Fiber lasers can weld a wide range of metals like copper, aluminum, stainless steel, and dissimilar metals Variations in part positioning can affect the focus of the laser beam Fiber laser technology is compact, minimizing floor space usage The laser beam path must be unobstructed, including by dust and fumes (which can distort the beam) The welding process is non-contact and requires little maintenance The reflectivity of the material has a strong effect on the efficiency of the laser process Lasers are operated by a controller, making them easy to automate with robots Optical components require protection, so consumables like a cover glass are needed Efficient use of the energy results in low heat input and causes minimal heat distortion The laser process must be optimized for each application as each metal has different fusion temperature (this is especially challenging when welding dissimilar metals)

Our laser experts know how to address these challenges and can help you.

Fiber Laser Welding Systems

A fiber laser welding system with the laser source, laser controller, and laser welding head. Image property of Laserax.

Optical & Electrical Components

Fiber laser welding uses a highly focused laser beam to join metals. The laser beam is generated through a system of electrical and optical components. Below is a list of the most important ones and their definitions.

• Power supply &#; The power supply converts electrical current into direct current (DC) to be used by the pump source.
• Laser source &#; The laser source includes the pump source, the gain medium, and the laser cavity. The pump source is an electrical device (typically an array of laser diodes) that converts electrical energy into laser light.  The gain medium is a fiber doped with a rare-earth element (like ytterbium). When pump light goes through the doped fiber, excited molecules generate light of a specific wavelength. That light is amplified in the laser cavity.
• Fiber optics cable &#; The fiber optics cable is used to guide laser light and deliver it to the right location on the processed surface.
• Fiber collimator &#; The collimator is a lens that transforms the light coming out of the fiber optics cable, converging it into a single direction to better focus its energy.
• Beam expender &#; The beam expender increases the size of the collimated laser beam. While the beam is less concentrated this way, the laser process tolerates surface and positioning variations better.
• Scanning head &#; The scanning head contains rotating galvo mirrors that control the direction of the laser beam.
• Focusing lens &#; The focusing lens is used to focus the laser beam on the processed surface. For example, a 200 mm focusing lens provides a good focus to weld at a distance of 200 mm.
• Focus shifter &#; Also called 3D head, the focus shifter is an optical assembly that can adjust the focal distance on the fly to account for large surface or positioning variations.

Other Components

Fiber laser welding machines include other components besides optical and electrical ones. Here&#;s a few that are common.

Wire feeder

A wire feeder can be used to add filler material during welding. This is a hybrid technology between MIG welding and laser welding. Wire feeding can help achieve high weld quality in certain cases, but it slows down the welding process, as the laser&#;s energy is used to melt more metal. Wire feeding is useful when the joint fit-up is not perfect and causes gaps; when solidification is too fast and causes cracks; and when you need to modify the mechanical properties of the weld.

Shield gas

To prevent oxidation of the welds, some manufacturers use a shield gas (like argon) in combination with laser welding. While using a shield gas is not always needed to achieve the required weld quality, it is always beneficial, as it helps reduce the number of defects in the welds. A good practice we use at Laserax is to develop the laser welding process without a shield gas and aim to achieve a good welding quality this way. If shield gas is added afterwards, it will only benefit the process.

Laser controller

The controller is an electronic device that controls the laser process by adjusting parameters like the laser power, pulse repetition rate, and pulse duration. It is also used to control safety features.

Fume extraction unit

Laser welding generates toxic fumes and contaminants that need to be extracted and filtered from the work environment. We have tips on how to perform fume extraction to maximize its efficiency and ensure safety.

Laser weld monitor

Different LWM methods exist to provide a real time analysis of the welding process. Laser weld monitoring (LWM) is essential to ensure a good weld quality and detect any deviations from good weld characteristics. It is used to define when welds need to be reworked (pass/fail).

Chiller

High-power lasers used for industrial welding generate heat that needs to be managed to maintain an optimal operating temperature and prevent safety issues. Depending on the laser power, different cooling systems can be used, such as an air chiller or a water chiller.

Continuous vs. Pulsed

Continuous and pulsed fiber lasers can both be used for laser welding. Their characteristics make them better suited for different applications. Here&#;s how they differ:

• Price: Continuous-wave lasers are less expensive
• Weld size: Continuous-wave lasers can produce larger welds more easily
• Heat-affected zone: Pulsed lasers have a lower heat affected zone
• Welding depth: Pulsed lasers can generate shallower, less intrusive welds

Single mode vs. Multimode

Single mode lasers are better for micro welding applications that demand increased precision like battery tab welding, while multimode lasers are ideal for larger workpieces that need to be processed faster. Here are their key differences.

• Precision: With their smaller spot size, single mode lasers offer increased precision for micro welding applications. Multimode lasers are less precise, as the laser beam is less focused.
• Energy density: Single mode lasers generate laser beams with a higher energy density due to the smaller beam size and better beam quality. While multimode lasers have a lower energy density, they can process larger surfaces faster.
• Heat-affected zone: Single mode lasers have a lower heat affected zone since heat is used more efficiently. Multimode lasers tend to generate lower quality welds with higher porosity.

Types of Fiber Laser Welding Systems

Handheld Laser Welding Machines

Handheld fiber laser welding machines are more accessible than ever. Similar to MIG and TIG welding systems, operators hold a &#;gun&#; to trigger and direct the laser beam. Even new, inexperienced welders can become productive quickly and create high-quality welds, as the learning curve is much lower.

Laser Welding Workstations

Workstations are semi-automated solutions that typically require an operator to load workpieces and launch the laser welding process. They are ideal to run small production batches, support product development, and develop a process optimized for a specific application. You can see an example of this with our laser welding workstation for battery manufacturers.

Robot Laser Welding Machines

Robot arms are frequently used in laser welding due to their precision and repeatability. Robot arms can be programmed to move the laser welding head to specific points on the workpiece, allowing it to weld large workpieces like car body parts, airplane wings and pipes.

Robot-Assisted Laser Welding Machines

In production lines, robot arms can be used to move and position clamping tools during laser welding, minimizing the amount of wait time for clamping. This also makes it possible to adapt the clamping positioning and pressure for each individual weld.

Our battery laser welding machine is a robot-assisted solution designed to help manufacturers scale up production and improve quality. Its automation and vision features allow it to weld at high speed. For cylindrical cells, our machine averages 100 ms/cell.

Fiber Laser Welding vs. Other Welding Methods

Fiber laser welding is increasingly used in today's production lines because of its many benefits over traditional welding methods. It offers higher precision and speed, better weld quality, and the ability to weld a wider range of materials.

The process is also environmentally friendly, reduces waste, and requires less maintenance than other welding methods. This makes it a cost-effective and sustainable solution for modern manufacturing.

Laser vs. Ultrasonic Bonding

Ultrasonic bonding is a method that uses ultrasonic vibrations to join surfaces together. You can find more information on how the method works here. Here are key differences between ultrasonic bonding and laser welding:

• Lasers are much faster. In EV battery production lines, they are at least 10 times faster than ultrasonic bonding, allowing manufacturers to scale up production and reduce the number of machines on the shop floor.
• Lasers produce stronger and more durable bonds.
• Lasers provide greater precision and control over the welding process, resulting in a higher quality weld.
• Ultrasonic bonding cannot be used to weld thick parts (usually limited to a few millimeters)
• Ultrasonic bonding can be used to weld plastics and malleable metals. Lasers can be used for a wider range of metals as well as to join dissimilar metals.
• Ultrasonic bonding requires a lower initial investment.

Laser vs. MIG Welding

MIG welding, or Gas Metal Arc Welding (GMAW), involves the use of a wire electrode that is consumed during the welding process to produce an electric arc and heat the metal being joined.

Fiber laser welding produces higher-quality welds than MIG welding, especially for applications that demand high precision and control. It is also a better solution for manufacturers looking to scale up production.

However, laser welding is more expensive and complex to set up.

Laser vs. TIG Welding

TIG welding, also known as Gas Tungsten Arc Welding (GTAW), uses a non-consumable tungsten electrode to create an electric arc and melt the metal being welded. A separate filler rod is used to add material to the weld joint as needed.

Unlike fiber laser welding, TIG welding requires a highly skilled welder to control the heat input and filler metal. The process is also slower and more labor-intensive.

Laser welding produces a smaller heat-affected zone, causing less damage to the material. However, TIG welding may be preferred for applications where appearance is important, as it produces more aesthetically pleasing welds.

Laser vs. Resistance Welding

Resistance welding passes an electric current through the metal parts being welded. As current goes through the metal, electrical resistance at the point of contact generates heat and causes the two metals in contact to melt. Electrodes can be used to create a spot weld, or rotating wheels can be used to create a seam weld.

Fiber laser welding generates better welding results than resistance welding. As a non-contact process, it produces very small and precise welds with minimal heat input, resulting in minimal distortion and a smaller heat-affected zone.

Resistance welding is harder to control due to the electrodes wearing off. It is more suitable, however, for small manual operations, since lasers come at a high initial cost.

Laser Welding Applications

With almost limitless laser configurations, laser welding technology is versatile and adaptable. This makes it effective in a range of industries, allowing for high-quality welds of both small and large workpieces.

Industry Examples of Applications Automotive Battery cells & modules, body in white, suspension system, transmission system Aircraft Turbine blades, frames, fuselage sections Electronics Printed circuit boards, battery cells & modules, housings, electrical contacts Medical Medical devices and implants Construction Window frames, plates, pipes Defense Frames, armor plates

The Growing Role of Fiber Laser Welding

As the demand for faster, more efficient, and more precise manufacturing processes continues to grow, fiber laser welding is likely to play an increasingly important role in many industries.

If you have a welding project that can benefit from a laser, contact our laser experts today.

What Is A Fibre Laser Welding Machine?

Steve from HPC Laser introduces us to the cutting-edge technology of fibre laser welding, a technique that&#;s been gaining attention on social media for its impressive results.

This innovative approach to welding offers a glimpse into the future of manufacturing, promising efficiency, precision, and safety.

If you want to learn more, please visit our website resin laser 3d printer.

Browse our range of fibre laser welding machines here.

Watch the full video here:

So, What Is A Fibre Laser Welding Machine?

A fibre laser welding machine uses similar principles to a fibre laser cutter and is an advanced piece of equipment designed for joining metal in place of a traditional MIG or TIG welder.

Utilizing a highly focused beam of light, this technology offers unparalleled accuracy and efficiency in welding applications.

The core principle behind fibre laser welding is the conversion of light into thermal energy, which is then applied to metal parts to melt and fuse them together.

The laser beam, characterised by its high intensity and narrow focus, allows for precise control over the welding process. This precision minimizes thermal distortion and eliminates the excess spatter commonly associated with traditional welding techniques, resulting in clean, high-quality welds.

Advantages of Fibre Laser Welding

One of the most significant benefits of fibre laser welding is its speed and the quality of welds it produces. Not only that, the welds look great, with very low profiles and zero spatter, eliminating the need for post-processing.

This technology also helps open up welding to the masses; even those without prior welding experience can achieve superior results, as demonstrated by Tom from the sales team, who successfully welded on his first-ever attempt.

Precision and Control

Laser welding provides exceptional precision and control over the welding process, allowing for the accurate joining of components with minimal heat input.

This precision is particularly beneficial for delicate or intricate parts, where traditional welding methods might cause damage or distortion.

High-Quality Welds

The weld joint produced by laser welding are high quality, with clean, consistent joins that exhibit minimal spatter and porosity. This results in stronger welds with better appearance, often eliminating the need for post-weld finishing.

Reduced Heat Input

One of the significant advantages of laser welding is its reduced heat input (and very concentrated heat source), which minimizes the heat-affected zone (HAZ) and thermal distortion.

This reduction in temperature is crucial for maintaining the integrity and properties of the materials being welded, especially in applications requiring high precision and minimal distortion.

Versatility

Laser welding can be applied to a wide range of materials, including metals that are difficult to weld using traditional methods. It&#;s also capable of joining dissimilar materials and thicknesses, offering flexibility across different applications and industries.

Increased Speed

Compared to conventional welding techniques, laser welding is faster, which can significantly enhance production efficiency. The speed of laser welding does not compromise the quality of the weld, making it an efficient option for high-volume manufacturing where welding speeds matter.

Automation and Integration

You don&#;t have to use handheld laser welding machines, laser welding systems can be easily automated and integrated into existing manufacturing lines, allowing for consistent and repeatable welds. This compatibility with automation technologies drives productivity and reduces labour costs.

Considerations & Challenges

As with all equipment, there will always be pros and cons. That aren&#;t many with fibre laser welding, but here we take a look at some of the minor pitfalls, and how you can mitigate them.

Gap Tolerance

One significant challenge with fibre laser welding is its intolerance for gaps between the parts being welded. Unlike traditional MIG welding, which can fill larger gaps between poorly fitting components, fibre laser welding requires parts to be closely fitted.

This limitation means that additional preparation may be necessary to ensure parts align well before welding, potentially increasing the prep time for certain projects.

Sensitivity of Laser Optics

The laser head, a critical component of the fibre laser welding machine, contains sensitive optics that are not as durable as the equipment used in more traditional welding methods. This sensitivity necessitates careful handling and maintenance to prevent damage.

Unlike a MIG welder, which can be somewhat roughly handled without significant risk of damage, the laser welding head requires a gentler approach.

Additional Safety Precautions

Safety is paramount in laser welding due to the potential for retinal damage. To address this, you will need specialised welding masks that protect against the specific wavelengths of fibre lasers, as well as infrared and UV radiation.

Fibre laser specific safety enclosures are recommended in order that other workers in the area are protected from the laser beam.

Additional protective gear is also needed, such as welding gauntlets and flame retardant overalls, mirroring the precautions taken with traditional welding methods.

Deskilling and Craftsmanship

Another advantage, which can be seen from different perspectives, is the level of deskilling involved with laser welding.

The technology simplifies the welding process to the extent that individuals without prior welding experience can produce high-quality welds with minimal training.

While this democratization of the skill can increase productivity and reduce training requirements, it also raises concerns about diminishing the craftsmanship traditionally associated with welding.

Some professionals in the field may view this as a negative aspect, feeling that the art and skill of welding are being eroded by technology that makes the process too simplistic.

Which Industries Typically Use Laser Welders?

The list is now so large that it would be impossible to name them all, but here are some of the biggest industries that rely on fibre laser welders:

• Automotive Industry: Essential for producing strong, lightweight components, laser welders are used in welding car bodies, engine components, and transmission parts, enhancing vehicle safety and fuel efficiency.
• Aerospace and Aviation: The aerospace sector relies on laser welding for joining engine parts, structural components, and intricate assemblies in aircraft and spacecraft, where durability under extreme conditions is critical.
• Medical Device Manufacturing: The precision and gentle handling of laser welding makes it perfect for assembling surgical instruments, implants, and other medical devices, where maintaining material integrity is vital.
• Electronics and Microelectronics: In electronics, laser welders are crucial for joining small components with precision, ensuring the integrity of electrical connections in semiconductors, batteries, and circuit boards.
• Jewellery Making: Laser welders allow for detailed work on precious metals, enabling jewellers to join intricate parts, perform repairs, and add fine details without damaging delicate designs.
• Tool and Die Repair: They offer a high-accuracy solution for repairing moulds, dies, and tooling, extending the life of expensive equipment and reducing manufacturing downtime.
• Research and Development: Laser welders support R&D efforts by enabling experimentation with different welding parameters and materials, facilitating the development of new products and materials.

Common Customer Questions About Laser Welding

During our exhibitions, we often get asked similar questions about laser welding, so here are some answers to those burning questions.

Are laser welders any good?

Absolutely. Laser welders are highly regarded for their ability to deliver precise, clean, and efficient welding results. They excel in producing high-quality joins with minimal heat input, reducing distortion and allowing for the welding of complex, delicate, or closely aligned components.

Is laser welding stronger than MIG?

Generally, yes. Laser welding typically results in stronger welds compared to MIG welding when correctly applied. This strength advantage comes from laser welding&#;s deep penetration and focused heat source, which minimizes the heat-affected zone and preserves the material&#;s integrity better than MIG welding.

Is laser welding easy?

Laser welding is considered much easier to master than some traditional welding techniques, thanks to its precision and the control it offers. With the right setup and some basic training, even new operators can produce consistent, high-quality welds, making it a user-friendly option for all.

Does laser welding use gas?

Yes, laser welding usually involves the use of a shielding gas, such as argon or nitrogen, to protect the weld zone from oxidation and other atmospheric contaminants. The choice of gas can affect the weld&#;s characteristics, including its appearance and integrity.

Our Machines: A Closer Look

The heart of HPC Laser&#;s technology are the LSW 2kW & 3kW fibre laser welding machines, designed for ease of use with its touchscreen operation and key-locked entry.

The machine features a built-in water chiller, eliminating the need for an external water supply, and uses industrial argon as a shielding gas which is readily available.

A versatile wire feed unit supports various spool sizes and wire types, allowing for infinite variability in wire speeds and the choice between pulse and continuous feed.

The key-locked entry ensures that only authorized personnel can access the machine, enhancing safety and security.

Material Compatibility and Power

This machine stands out for its broad material compatibility, capable of welding carbon steels, stainless steel, aluminium, brass, and copper, with or without filler wire.

Its power efficiency is excellent, requiring approximately 400 watts per millimeter thickness of material for full penetration, making it suitable for welding up to 5mm of carbon steel, but slightly less for aluminium and other metals.

Summing It Up

HPC Lasers fibre laser welding machine represents a significant advancement in welding technology, offering a blend of speed, precision, and ease of use.

While it introduces new considerations in terms of operation and workpiece preparation, the benefits it brings to the table&#;ranging from improved safety, reduced energy consumption and most importantly speed, outweigh the downsides.

As the industry continues to evolve, the adoption of fibre laser welding technology promises to redefine standards of quality, efficiency, and accessibility in metal fabrication.