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Published: August 1, 2007
The idea of lasers might bring to mind images of cheesy sci-fi movies set on the moon, but lasers are used today as a method of welding. Laser welding gives welders an advantage over using conventional methods of joining two pieces of metal. Advantages of laser welding include higher welding speeds, low distortion and lower heat input.
These are all improvements that have allowed the technique of laser welding to make its way into the automotive and aerospace industries.
The process of laser welding involves pointing a high energy laser beam of heat at a point to cause the material to liquefy. When the laser is pointed away, the substance is allowed to cool and change back into a solid. The laser welding process takes two forms: laser penetration welding and laser conduction welding.
Laser penetration welding is done by focusing the laser welding machine's beam on a fixed point in a stack of material and shooting the laser beam until the material has changed to its liquid state. A hole forms through the stack after some of the material has vaporized, and this marks the point where the material will join after it has solidified. The other type of laser welding, called laser conduction welding, sees the welder focusing the laser on the joint between two materials. The conventional solid-to-liquid-and-back process occurs, resulting in two materials joined at that location. This type of laser welding is used for continuous seam welding in addition to spot welding.
The actual laser welding equipment varies as well. Two common technologies are CO2 (carbon dioxide) and YAG laser welding machines. These each use different lasing mediums and have their own advantages and disadvantages. CO2 lasers combine carbon dioxide, nitrogen and helium for the lasing medium. These high-speed cutting lasers can cut non-metallic materials as well as the typical metallic ones. The beam is transmitted via mirror and cuts anywhere from 0.5 to 2 kilowatts.
For their lasing medium, YAG lasers utilize a yttrium aluminum garnet bar with added neodymium. YAG lasers, by contrast, cannot cut non-metallic materials but can transmit their lasers from fiber optics as well as mirrors. Like CO2 lasers, these can exhibit up to 2 kilowatts of power. According to Engineers Edge, both YAG and CO2 laser welding machines are capable of operating in either pulse or continuous modes; pulse mode means the laser flickers or pulses on the welding point, while laser welding machines operating in continuous mode have the laser perpetually shining on the point.
Laser welding equipment can be used on a variety of materials, from copper to titanium to nickel. Certain laser welding machines will work better with some materials. Myachi Unitek, a supplier of laser welding equipment, manufactures several laser welding machines with different strengths and weaknesses. The LW300AH Aluminum laser welding machine produces good welds on materials such as phosphor bronze, titanium and tantalum. However when it comes to tungsten, this laser welding machine will not produce strong welds. It can do the job, but the welds will be brittle. Additionally, when welding stainless steel, the user should take the type of laser fitting into account. The LW300AH can use several types of lasers, and while a couple, such as the 304 and 304L, are optimum choices for welding stainless steel, other lasers such as those in the 400 series should be tested first.
Laser welding is a heat-intensive process and thus can be dangerous. The process presents both radiation and fire hazards, so welders should take the proper safety precautions to ensure the laser welding process is safe and successful. The vaporizing metals can also release toxic fumes, so welders should wear face masks to avoid breathing them in. The laser welding machine should come with safety recommendations from the manufacturer, but even a little common sense will make the process run more smoothly.
Sources:
Xie, J. "Weld Morphology and Dual-Beam Welding." 18 July 2007. http://files.aws.org/wj/supplement/11-2002-XIE-s.p df.
"Laser Welding Overview." EngineersEdge.com. 2002-2007. Engineers Edge. 18 July 2007. http://www.engineersedge.com/manufacturing/laser_w elding.htm.
"Suitability Of Materials for Nd: YAG Pulsed Laser Welding." MiyachiUnitek.com. 2007. MiyachiUnitek. 18 July 2007.
http://www.miyachiunitek.com/res_products/pdf/Su itability%20of%20Materials%20for%20welding.pdf.
LW300AH Aluminum High Speed Laser Welding. MiyachiUnitek.com. 2007. Miyachi Unitek. 18 July 2007. http://www.miyachiunitek.com/res_products/pdf/Apps _LW300_600.pdf.
"Laser Welding and Cutting Safety." Aws.org. 1998. American Welding Society. 18 July 2007. http://www.aws.org/technical/facts/FACT-19.PDF.
The process of laser welding involves pointing a high energy laser beam of heat at a point to cause the material to liquefy. When the laser is pointed away, the substance is allowed to cool and change back into a solid. The laser welding process takes two forms: laser penetration welding and laser conduction welding.
Laser penetration welding is done by focusing the laser welding machine's beam on a fixed point in a stack of material and shooting the laser beam until the material has changed to its liquid state. A hole forms through the stack after some of the material has vaporized, and this marks the point where the material will join after it has solidified. The other type of laser welding, called laser conduction welding, sees the welder focusing the laser on the joint between two materials. The conventional solid-to-liquid-and-back process occurs, resulting in two materials joined at that location. This type of laser welding is used for continuous seam welding in addition to spot welding.
The actual laser welding equipment varies as well. Two common technologies are CO2 (carbon dioxide) and YAG laser welding machines. These each use different lasing mediums and have their own advantages and disadvantages. CO2 lasers combine carbon dioxide, nitrogen and helium for the lasing medium. These high-speed cutting lasers can cut non-metallic materials as well as the typical metallic ones. The beam is transmitted via mirror and cuts anywhere from 0.5 to 2 kilowatts.
For their lasing medium, YAG lasers utilize a yttrium aluminum garnet bar with added neodymium. YAG lasers, by contrast, cannot cut non-metallic materials but can transmit their lasers from fiber optics as well as mirrors. Like CO2 lasers, these can exhibit up to 2 kilowatts of power. According to Engineers Edge, both YAG and CO2 laser welding machines are capable of operating in either pulse or continuous modes; pulse mode means the laser flickers or pulses on the welding point, while laser welding machines operating in continuous mode have the laser perpetually shining on the point.
Laser welding equipment can be used on a variety of materials, from copper to titanium to nickel. Certain laser welding machines will work better with some materials. Myachi Unitek, a supplier of laser welding equipment, manufactures several laser welding machines with different strengths and weaknesses. The LW300AH Aluminum laser welding machine produces good welds on materials such as phosphor bronze, titanium and tantalum. However when it comes to tungsten, this laser welding machine will not produce strong welds. It can do the job, but the welds will be brittle. Additionally, when welding stainless steel, the user should take the type of laser fitting into account. The LW300AH can use several types of lasers, and while a couple, such as the 304 and 304L, are optimum choices for welding stainless steel, other lasers such as those in the 400 series should be tested first.
Laser welding is a heat-intensive process and thus can be dangerous. The process presents both radiation and fire hazards, so welders should take the proper safety precautions to ensure the laser welding process is safe and successful. The vaporizing metals can also release toxic fumes, so welders should wear face masks to avoid breathing them in. The laser welding machine should come with safety recommendations from the manufacturer, but even a little common sense will make the process run more smoothly.
Sources:
Xie, J. "Weld Morphology and Dual-Beam Welding." 18 July 2007. http://files.aws.org/wj/supplement/11-2002-XIE-s.p df.
"Laser Welding Overview." EngineersEdge.com. 2002-2007. Engineers Edge. 18 July 2007. http://www.engineersedge.com/manufacturing/laser_w elding.htm.
"Suitability Of Materials for Nd: YAG Pulsed Laser Welding." MiyachiUnitek.com. 2007. MiyachiUnitek. 18 July 2007.
http://www.miyachiunitek.com/res_products/pdf/Su itability%20of%20Materials%20for%20welding.pdf.
LW300AH Aluminum High Speed Laser Welding. MiyachiUnitek.com. 2007. Miyachi Unitek. 18 July 2007. http://www.miyachiunitek.com/res_products/pdf/Apps _LW300_600.pdf.
"Laser Welding and Cutting Safety." Aws.org. 1998. American Welding Society. 18 July 2007. http://www.aws.org/technical/facts/FACT-19.PDF.
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