The Benefits of Using fiber laser welding machine

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.

Laser welding has become a vast approach with the evolution of new laser welding technologies. Fiber laser welding is the latest technique that revolutionizes the welding process. This technique is widely applicable due to its precision and efficiency.

In this blog post, you'll discover the ins and outs of fiber laser welding. You'll also explore its applications and how you can choose the best fiber laser welding machine. So, let's get into it.

What is Fiber Laser Welding?

Fiber laser welding is a laser welding technique that employs optical fibers to transform ordinary light into laser beam. The optical fibers are made of phosphate or silicate glass and doped with ytterbium and neodymium. The laser diodes generate light by using electrical energy. A coupler merges the light from multiple diodes to create an intense, concentrated laser beam in the fiber optic cable.

The fiber cables direct the intense laser beam to the welding head, from where it is directed to the base metal. The metal absorbs the high energy of the laser beam and melts. On cooling, the metal workpieces fuse to create a strong weld.

5 Types of Fiber Laser Welding Processes

Fiber laser welding is a versatile approach. It involves various laser welding modes depending on feed speed, beam focus, and power setting. The following are some common fiber laser welding processes:

1. Conduction-Mode Welding

In this process, the heat energy required for welding is transferred to the workpiece through conduction. Conduction-mode welding offers limited weld depth as the heat is conducted through the material. This mode is applicable for fusing thin metals and spot welding.

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Sufficient power density in conduction-mode welding results in smooth melting of the metal. It creates perfect welds that do not need post-treatments, like grinding or finishing. You can employ this welding mode for sealing batteries and corners of electrical devices.

2. Keyhole-Mode Welding 

The keyhole welding process is characterized by the formation of a keyhole. Excessive laser energy deeply penetrates the workpiece and vaporizes the material. The high power density of the fiber laser results in effective joining. The molten metal from the surrounding fills the keyhole, creating a strong weld. This mode is used for creating deep welds for various heavy equipment.

3. Pulsed-Wave Welding 

Pulsed fiber laser welding involves the delivery of laser energy in short pulses. In this mode, the pulsed fiber lasers result in high peak powers to create spot welding. The short duration and low heat make it a perfect fit for spot welding.

It is also an effective technique for welding heat-sensitive materials and reflective metals as the intermittent heat dissipates. This approach is employed in applications that demand minimal heat distortion and precise weld depth.

4. Continuous-Wave Welding

In this mode, the fiber laser welding machine emits a continuous laser beam. The continuous laser energy delivers a stable weld pool with deep penetration. Continuous welding with high-speed results in effective welds for thin materials. The high feed rate limits heat distortion. A precise balance between power and feed speed is crucial for effective penetration and strong welds.

5. Hybrid-Laser Welding

According to Wikipedia, this process of fiber laser welding combines laser welding with traditional welding methods, like gas metal arc welding, metal active gas welding, or plasma welding. This mode boosts the processing speed, leading to greater penetration depth. It also enhances tolerance to joint fit-up and weld quality.

The combination of the two approaches results in low energy consumption and effective control of the material. This mode also minimizes the production cost. It is employed in applications requiring deep welds, like construction, transportation, and shipbuilding.

6 Advantages of Fiber Laser Welding

Manufacturers opt for fiber laser welding due to its effectiveness and advantages over traditional welding techniques. Here are some benefits of employing fiber laser welding machines for the welding process:

1. Creation of Complex Welds

Creating complex welds with traditional methods is a daunting task for welders. High power and focused laser beam enable you to create intricate welds at hard-to-reach spots. It also allows you to work with various types of materials and varying thicknesses.

Moreover, you can use it to create complex prototypes that need precision. You can adapt fiber laser welding machines to new designs with minimum adjustment.

2. Material Versatility

Traditional welding techniques have limited applications. However, fiber laser welding applies to a wide range of materials, including metals, non-metals, thermoplastics, organic compounds, and composites. This technique also enables you to accomplish weld dissimilar metal welding. It makes it a perfect fit for industries where you need to join different materials.

3. Precision and Accuracy

Fiber laser welding can work at the micro-level. You can weld small spots with minimal heat distortion with this technique. Minimum heat affected zone and maximum control over the welding process allows you to achieve strong welds.

Laser welding also creates deep keyholes to create deep welds with smooth welding seams. Moreover, the speed of the process helps you create intricate welds in a short duration.

4. Low Footprint 

The latest fiber laser welding machines have compact designs. They occupy less space compared to traditional laser machines. Most traditional lasers are bulky and need a large space.

A low footprint also enables you to accommodate the equipment in your existing space. This feature of fiber laser machines facilitates manufacturers to optimize their floor space and utilize it efficiently. It is valuable for modern manufacturing units as it organizes your production space.

5. Lower Distortions

Fiber laser welding limits heat distortion. A focused laser beam affects the required area, preventing the surrounding material from melting. It minimizes the risks of warping or distortions. Employing shielding gas also helps minimize heat distortion by quickly cooling the welds.

This feature makes it a valuable asset for industries where you need to maintain high-quality standards. Minimum distortion also contributes to improving the structural quality of the workpiece. It reduces the need for post-welding treatments.

6. Easy to Master

Unlike traditional welding methods that involve intricate welding techniques, fiber laser welding is a user-friendly approach. You don't require extensive training to master it. You can learn to operate the laser machine and create perfect welds in a few training sessions. Simple operation makes it convenient for manufacturing facilities to train new employees and boost their productivity.

Comparison with Other Welding Methods

Fiber laser welding is gaining prominence due to excellent control over the welding process and extraordinary production speed. Here is a comparison of fiber laser welding with other welding processes:

Comparison With Gas Metal Arc Welding (GMAW) Welding

Gas metal arc welding (GMAW) employs an electrode wire during the welding process. The electrode generates an electric arc that heats the workpieces. The electrode is consumed during the process of welding. An inert gas is applied to prevent the weld pool from contaminating. On cooling, the metal fuses to create a weld.

In contrast, fiber laser welding employs a laser welding system to create high-quality welds. These welds are stronger than those created by gas metal arc welding. It makes fiber laser welding a preferable choice for applications where precision and strength of welds are paramount.

Comparison With Tungsten Inert Gas (TIG) Welding

Tungsten inert gas (TIG) welding is another traditional welding technology. It employs a tungsten electrode to generate an electric arc. However, the electrode is non-consumable. A filler metal wire is used to fill the gap between the workpieces during welding. This process requires skills to control the heat input. A slight mistake in handling the heat input and filler metal can damage your workpiece.

In contrast, fiber laser welding machines create a limited heat-affected zone, resulting in precise melting and fusion of workpieces. It minimizes the risks of damage to the material as it is easy to handle. However, TIG welding is preferred over fiber laser for applications where you need aesthetically pleasing welds.

Comparison With Resistance Welding

Resistance welding creates resistance between the metal workpieces by passing an electric current. As the current is passed through the metal, the resistance created generates heat. This heat energy is sufficient to melt workpieces. You can also employ electrodes for spot welding. However, the weld quality is not up to the mark. Moreover, it is hard to control as the electrode can wear off during the process.

On the other hand, fiber lasers create smooth welds. The focused, non-contact process creates minimum heat-affected area and limited thermal distortion. It results in high-quality welds.

Applications of Fiber Laser Welding Technology

Fiber laser machines are extensively used in several industries. The following are some applications of fiber laser welding:

1. Aerospace Industry

The aerospace industry requires robust welds. You can't achieve complex welds in turbines, frames, blades, and other structural elements with traditional welding. Fiber laser welding allows you to create spot welding. It is also used for joining various materials, like titanium, that you can't weld with traditional welding technology.

2. Automotive Industry

Fiber laser welding has boosted automotive manufacturing by offering high feed speed and control over the welding process. It is employed for joining various dissimilar metals, like aluminum and mild steel, to create engine parts. Moreover, fiber laser welding offers better joint strength that ensures the durability of the automobiles.

3. Medical Device Manufacturing

Manufacturing medical devices require exceptional precision. Fiber laser welding works at the micro-level and allows you to create intricate structures, like implants. You can also use a handheld laser welding machine to create a weld at the required spot without distortion.

4. Construction Sites

In the construction sector, fiber laser welding joins structural components. Precise weld creation ensures the structural integrity of metal frames. Its high speed and minimum thermal distortion provide high-quality welds.

5. Defense Sector

The military and defense sector also employs fiber lasers to create heavy machinery and robust armor. This laser welding helps you create precise welds for strengthing metal frames. It also ensures the structural integrity of various military equipment.

Cost of Fiber Laser Welding

The cost of fiber laser welding varies. It depends on laser power, focus, and speed. Customization and configuration of the machine also affect its cost. The cost of automated fiber laser welding machines ranges from $15k to $40k. Handheld laser welding machines are a cost-effective investment. Their costs range from 1k to 10k, making it an affordable option.

In addition to the initial investment, you need to consider the operational and maintenance costs. A 4kW fiber laser welding machine has an average operational cost of about $6.24 per hour. It includes the power consumption your laser consumes during welding.

A 1kW laser welding machine requires an average of 5kw per hour of electricity. A 3kW laser needs about 12kw per hour of electricity. Choosing an energy-efficient laser can help you significantly minimize the operational cost.

Your machine also needs regular maintenance. It's nozzle and lens consumes over time and you need to buy new ones for smooth operation. Moreover, routine inspection and cleaning are also crucial. Maintenance of a fiber laser welding machine costs a few hundred dollars. It usually ranges from $300 to $500 depending on the condition of your machine.

How to Choose the Right Fiber Laser Welding Equipment?

Several factors are involved in determining the right fiber laser welding machine for your needs. Here are the factors you should consider when choosing the right fiber laser welding machine:

1. Material Compatibility

Material compatibility is a crucial aspect of determining the type of laser machine. Fiber laser machines are compatible with welding metals, including aluminum, copper, and steel.

However, they are not effective for welding non-metals and thermoplastics. Welding non-metals and thermoplastics with fiber laser results in weak welds. You need to consult the manufacturer to learn about the material compatibility of your machine.

2. Material Thickness

Material thickness is another important factor. Each laser welding machine is designed for welding up to a particular thickness. According to LinkedIn, the power of laser welding equipment affects the thickness of the material it can weld. Check the manufacturer's instructions to learn about the maximum thickness it can handle.

3. Welding Application

Various laser welding machines are designed for particular welding applications, like spot welding, 3D welding, or seam welding. Look for a fiber laser that you can use for multiple applications.

FAQs

1. What are the parameters for fiber laser welding?

Crucial parameters for a fiber laser welding system include laser power, speed, beam focus, and beam diameter,

2. What precautions should be taken during laser welding?

Laser welding creates a high-energy laser beam. Never direct the laser beam to your eyes. Avoid directly looking at the laser beam. Wear protective gear to prevent the harmful effects of the laser beam.

We have prepared an article on laser safety.

3. What is the principle of fiber laser?

A fiber laser contains optical fibers that generate light from electrical energy. The optic fiber cables absorb light beams from multiple pump laser diodes and emit an intense laser beam.

Conclusion

Fiber laser welding is an innovative technology that can transform manufacturing processes. Its precision and efficiency enable you to create strong welds. You can employ various modes of fiber laser to create stunning results. It is an easy-to-use technology, and you can learn to operate it in a few sessions. However, choose a reliable fiber laser welding machine.

Unleash the Potential of Fiber Laser Welding with Baison Laser!