Laser beam

welding

Laser :
Light Amplification By Stimulated Emission
Of Radiation
Electrons are atomic particles that exist at specific
energy levels. These energy levels are unique and are
different for every atom or molecule.
Electrons in outer rings are at higher energy levels than
those in the inner rings. A flash of light can bump
electrons to higher energy levels by the injection of
energy. When an electron drops from an outer ring to an
inner ring or level, the excess of energy is given off as
light.
The wavelength or the color emitted is related to the
amount of energy released.

Part of the laser light passes through

the semi-reflecting mirror and performs
the welding function.
produces a very high energy density
light beam, many times higher than is
possible with normal light
The energy -hot light- created at
the focal point in a relatively short time
(0.5 to 20 ms) heats the metal beyond
its melting point and thus enables a
weld.

Laser Power
Joules: The hot light energy
output is measured in joules.
This industry term by
definition is the capacity
for doing work. Hot light
energy output is determined
by the amount of voltage and
pulse-length selected by the
operator

Welding effects:
When a pulse of hot light
energy penetrates an
alloy, the resulting affect
creates gaseous, liquid,
and molten zones in the
bombardment area

Why do we need laser for welding?

Laser beam welding:
Traditional welding:
Natural limitations to speed and
productivity
Thicker sections need multi-pass
welds

A large heat input

Results in large and unpredictable
distortions
Very difficult to robotize

High energy density input process

single pass weld penetration up
to inch
High aspect ratio
High scanning speeds
Precisely controllable (close
tolerence: 0.002 in.)
Low heat input produces low
distortion
Does not require a vacuum (welds at
atmospheric pressure)
No X-rays generated and no beam
wander in magnetic field.
No filler metal required (autogenous
weld and no flux cleaning)
Relatively easy to automate
Materials need not be conductive

Typical commercial lasers for welding

1.

CO2 Laser

2.
Nd3+:YAG Lasers
3. Diode Laser

CO2 Laser: Characteristics

Wavelength

10.6 m; far-infrared ray

Laser Media CO2N2He mixed gas (gas)

Average
45 kW (maximum)
Power (CW) (Normal) 500 W 10 kW
Merits

Easier high power (efficiency: 10

20%)

YAG Laser

YAG Laser Application: Automobile Industries

Effect parameters while

welding metals is as follows:
The voltage first influences the welding
depth.
The pulse length predominantly influences
the diameter of the welding point.
The focus influences the welding depth as
well as the diameter of the welding spot.
When increasing the diameter, the welding
depth is reduced at the same time.

Primary Adjustable Parameters and

Their Effects
Primary Controllable Parameters
Laser Beam Energy Output Characteristics
(i) Voltage
(ii) Pulse Duration
Laser Focus Characteristic
(iii) Laser Beam Diameter

Change in Voltage

Increased voltage results in deeper

physical penetration with less melting
due to physical pressure

Change in Beam Diameter

Change in Pulse Duration

Increased pulse duration results in

deeper and wider melting

Change in Voltage and Pulse

Duration

Simultanous increase in voltage and

pulse duration results in deeper melting
Increased beam diameter results in
shallow soft penetration and wide, but
soft melting

Lasers Beam Welding:

Types of LBW

Conduction Welding
Description
Heating the workpiece above the melting
temperature
without vaporizing

Heat is transferred into the material by

thermal conduction.
Characteristics
Low welding depth
Small aspect ratio (depth to width ratio is around
unity)
Low coupling efficiency
Very smooth, highly aesthetic weld bead
Applications
Laser welding of thin work pieces like foils, wires,
thin tubes, enclosures, etc.

Lasers Beam Welding:

Types of LBW

Keyhole Welding

Description
Heating of the workpiece above the
vaporization temperature and forming of a
keyhole

Laser beam energy is transferred deep

into the material via a cavity filled with
metal vapor

Hole becomes stable due to the

pressure from vapor
generated
Characteristics

High welding depth

High aspect ratio (depth to width

ratio can be 10:1)

High coupling efficiency

Lasers Beam Welding:

Laser welding unit

Beam
Delivery
unit

Schematic
Diagram
Beam Delivery Unit

Laser

Processing
Optics

Workpiece Positioning Unit

Joining Metals

Joint Preparation: To ensure a

strong laser welding joint it is
important to properly evaluate your
application and material thickness
first before selecting one of the joint
preparation methods

Bonding the joint: Strong

homogenous allow flow is achieved using
the appropriate parameter combinations
and the 50% overlap firing method. This
ensures a structurally sound joint while
virtually eliminating the possibility of
gaseous pockets or cold welds

Surface filling the joint: laser

welding vaporizes some of the alloy.
Filler material is used to fill these
voids. The filler material should be the
same alloy if possible. Filler wire
diameter should be no lager than
0.50mm or .020.

Filler Materials

Large gaps: Require fabricating a

large insert (often thick wire or
casted piece) of the same material

Small gaps: often require a quick

application of a thin filler wire to
correct or complete the laser
welding application

Shallow blemishes: require a

quick application of a thin filler wire
to correct the laser welding
application

Porosity

Deep porosity: can be repaired

in two steps: first using high
voltage-short pulse duration with
a tight beam diameter, burnout
any investment remaining and
expose the complete porosity
pocket; Second, use the filler
material to refill the porosity
pocket

Hammering and
Smoothing

After the core laser welding

process has been completed, it
is recommended to adjust to a
lower power, wide laser pulse
diameter and medium to fast
auto-pulsing setting. This will
smooth over or hammer the
surface which eliminates most
rough surfaces and reduces
secondary finishing techniques
to the laser welded area.

Thank You for

Patience Hearing