Laser Welding Applications Across Industries
Key Points
Laser welding is a rapid and accurate fabrication technique widely adopted across major industries, including automotive, aerospace, medical, and electronics.
- Specific applications range from joining body panels and complex powertrain components in the automotive sector to micro welding delicate implants and surgical instruments in the medical field.
- The efficiency of laser welding often results in significant cost reductions, especially when compared to traditional methods like TIG welding.
Modern production processes require both speed and accuracy to keep up with demand and maintain quality levels. Any system that you incorporate into your workflow must therefore meet these criteria, which is why laser welding has become such a relied-upon method for many industries. Below, we’ll dive into the many benefits of laser welding and how it aids sectors like automotive, aerospace, healthcare, electronics, and more.
Core Advantages of Laser Welding for Manufacturing
All industries that benefit from laser welding do so at the manufacturing level, so the greater manufacturing field is one of the biggest beneficiaries of laser welding. The process involves using a concentrated laser beam to melt and fuse parts together as an alternative to traditional welding techniques.
Some of the key benefits to laser welding include:
- Producing highly precise welds
- Creating minimal heat-affected zones (HAZ), resulting in reduced damage and distortion
- Making strong, durable welds that stand the test of time
Eliminating the need for post-weld grinding and finishing in many cases, reducing strains on workflow and labor costs
Laser Welding Techniques: Matching Penetration to Industrial Need
Laser welding can be broken down into two subsets: conduction welding and keyhole welding.
Conduction Welding
- Uses the process of heat conduction to melt materials
- Features low-energy density that produces smooth, shallow welds
- Distributes heat so welding materials can melt but the heat does not penetrate the workpiece itself
- Laser welding can be broken down into two subsets: conduction welding and keyhole welding.
- Is ideal for producing delicate parts and those sensitive to heat, such as medical devices, electronics, jewelry, and more
Keyhole Welding
- Features high-energy density with the laser’s peak power surpassing 1.5MW/cm2, heating material past the fusion point, vaporizing a portion of it, and then allowing a free flow of molten material
- Produces narrower and deeper penetration by the laser beam, ideal for sections that require added strength in the weld
- Creates a filament of vaporized material, called a keyhole, which clears a path for the laser light
- Is ideal for the more robust needs of welds found in aerospace and automotive manufacturing
Automotive Engineering: Achieving Lighter, Stronger Components
The automotive field requires strong, precise welds to enhance vehicle performance, facilitate safety measures, and produce optimal fuel efficiency. Laser welders are therefore an ideal manufacturing solution, with different types of laser systems being used for distinct applications, including fiber lasers, CO2 lasers, YAG lasers, and more.
Some of the key applications automotive manufacturers use laser welding for include:
- Body panels
- Doors
- Chassis
- Powertrain parts
- Alternators
- Fuel injectors
- Filters
- Solenoids
Aerospace Engineering: High-Stress Applications and Weight Reduction
Because of the needs for extreme accuracy and reliability in the aerospace sector, any manufacturing process chosen must be able to produce precise, repeatable results within tight tolerances. Thankfully, laser welding is up to the task, meeting these needs while enduring the tough and high-stress conditions found within manufacturing plants.
Some of the common applications for laser welding in aerospace include use on:
- Fuel tanks
- Hydraulic systems
- Engine parts
- Turbine blades
- Lightweight structural assemblies
Along with this, aerospace operations often use filler wire to produce welds that are fatigue resistant, allowing them to use fewer rivets in aircraft, cutting down on weight.
Medical Device Manufacturing: Precision, Cleanliness, and Micro Welding
Precision is also required in the production of medical devices, but so is cleanliness and sterility. Medical device manufacturers need to use systems that can deliver reliable welds without marring the full workpieces, something laser welding excels at.
Core applications in this space include:
- Surgical instruments
- Pacemakers and other medical implants
- Diagnostic equipment
- Catheter shafts
- Hypodermic tubing
- Diaphragms and bellows
Electronics and Electrical Equipment: Solving Intricacy Challenges
Some of these components are welded via micro welding techniques, which can perform work less than 1 mm deep.
Yet another field requiring precision is the electronics industry, as the small nature of electronic components and electrical systems means that welds have to achieve tight tolerances and meet exacting standards.
Some of the applications that electronics companies use laser welding for include:
- Soldering circuit boards
- Packaging microelectronics
- Connecting batteries
Jewelry and Tool and Die: Production and Repair
Within the jewelry industry, laser welding has been used to produce intricate and precise pieces, but also to repair them. Operators are even able to approach the welds with a “free moving” approach, adjusting the workpiece directly under the stationary beam while work is being performed.
For the tool and die sector, laser welding helps to extend the life of essential mold tools, and also removes the need for preheating prior to repair work. By eliminating preheating, the internal stresses that develop from conventional heating methods are greatly reduced, making for more robust components.
Looking to Improve Operations with Laser Welding? ACSYS Systems Can Help!
At ACSYS, we supply a wide range of laser systems designed for laser welding and many other key laser production processes. Our welding systems achieve precise and efficient welds of the finest quality without the need for additional materials.
Plus, our laser machines are adept at metal welding, facilitating both heat conduction welding and keyhole welding processes. They can also conduct plastic welding, creating fusion bands between plastic components.
No matter what industry you’re in or what your welding needs are, our efficient systems are ready to get the job done.
FAQs About Laser Welding
Can laser welding be used to join dissimilar metals and nonmetallic materials?
Yes, laser welding can join dissimilar metals like titanium-aluminum or brass-copper, often by arranging them to physically lock together, and it can also work with composite materials, glass, and ceramics, though ceramics may require preheating.
What are the main disadvantages and skill requirements associated with laser welding machinery?
Disadvantages include a larger initial investment, the needs for operator training, and the skill required to bring about precise beam positioning.
What role do shielding gas and filler materials play in the laser welding process?
Shielding gas, such as argon or helium, is commonly used to protect the molten weld pool from atmospheric contamination (oxygen and nitrogen). Filler materials are not always required but can be added to bridge gaps or enhance the weld strength and adjust its chemical composition.
Contact ACSYS for Cutting-Edge Welding Systems
The team at ACSYS is ready to supply you with precision equipment that can streamline and improve your welding operations. Reach out to us today and we can assess your needs and make recommendations.