What are the laser welding processes?
Aug 12, 2025
Laser welding is a new welding method primarily designed for welding thin-walled materials and precision parts. It can perform spot welding, butt welding, lap welding, and seal welding. Its characteristics include a high aspect ratio, a small weld width, a small heat-affected zone, minimal deformation, and fast welding speeds. The welds are smooth and aesthetically pleasing, requiring minimal or no post-weld treatment. The welds are high-quality, free of porosity, can reduce and optimize impurities in the base metal, and can be refined after welding. The weld strength and toughness are at least equivalent to, or even exceed, the base metal. Precise control and a small focused spot allow for high-precision positioning and ease of automation. Laser welding can also be used to weld certain dissimilar materials.
1. Laser Autogenous Welding
Laser welding utilizes the excellent directionality and high power density of a laser beam. An optical system focuses the laser beam into a small area, creating a highly concentrated heat source within a very short time. This melts the materials being welded and forms a strong weld point and seam. Laser welding: High aspect ratio; high speed and precision; low heat input and deformation; non-contact welding; unaffected by magnetic fields, no vacuum required.
2. Laser Welding with Wire
Laser welding with wire is a method of pre-filling the weld with a specific welding material, then melting it with laser irradiation, or adding the welding material simultaneously with laser irradiation, to form the weld joint. Compared to welding without wire, laser welding with wire overcomes the stringent requirements for workpiece processing and assembly; it can weld thicker and larger parts with lower power; and by adjusting the filler wire composition, the microstructure and properties of the weld area can be controlled.
3. Laser Welding on the Fly
Remote laser welding is a laser welding method that uses a high-speed scanning galvanometer lens for long working distances. It offers high positioning accuracy, short welding times, fast welding speeds, and high efficiency. It avoids interference with welding fixtures and reduces contamination of optical lenses. It can also customize weld shapes to optimize structural strength. Generally, the welds lack gas shielding, resulting in significant spatter. It is primarily used for thin, high-strength steel plates, galvanized steel plates, and other products such as body panels.
4. Laser Brazing
A laser beam emitted by a laser generator is focused on the surface of the welding wire, heating it and melting it (while the parent material remains unmelted). This heat wets the parent material, fills the gap between the joints, and bonds with the parent material, forming a weld and achieving a good connection.
5. Laser Oscillating Welding
The laser is controlled by the oscillation of the reflective lens inside the welding head, stirring the weld pool and promoting gas escape from the pool, thereby refining the grain size. This also reduces the laser welding's sensitivity to gaps between the incoming and outgoing materials. It is particularly suitable for welding aluminum alloys, copper, and dissimilar materials.
6. Laser-Arc Hybrid Welding
Laser-Arc Hybrid Welding combines laser and arc heat sources, which have distinct physical properties and energy transfer mechanisms, to create a new and highly efficient heat source.
Features of Hybrid Welding:
1. Compared to laser welding, it offers enhanced bridging capability and improved microstructure.
2. Compared to arc welding, it offers reduced deformation, higher welding speeds, and deeper penetration.
3. It combines the strengths of each heat source while compensating for its own deficiencies, achieving a value of 1+1 greater than 2.
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