Is laser welding the best option for your job?

Is laser welding the best option for your job?

Laser welding is just one of many welding techniques used in many industries. Each system has its strengths and weaknesses, and there is still much debate about which is "better". This article examines various details of the three main conventional welding methods and compares them to laser welding.

It then explores how certain common welding functions perform and recommends situations where a laser system would be the most effective and therefore the best option for the job.

Conventional Welding vs Laser Welding - Which Is Better?

“If laser welding is generally faster and higher quality, why should we care about conventional welding?” The answer is not so simple. Deciding which one is better depends a lot on the worldview and the personal opinion and usage of the person asking the question.

Today, the most common conventional welding methods are typically Metal Inert Gas (MIG) welding, Tungsten Inert Gas (TIG) welding, and spot welding (also known as resistance spot welding). All three are threatened by advances in laser welding systems, but all three are still in widespread use.

For MIG welding, the consumable is a continuous supply of wire. This process of continuously adding material to enhance the welding process makes the MIG method ideal for fillet welding. Indeed, some believe that all parts must be more precise and precise in order to be fillet welded with a laser. So, at least for now, many are of the opinion that not only can MIG produce accurate vertical or fillet welds, but it may actually outperform laser welding.

The automation process of MIG welding is also considered easy. There are a few simple things you can control, like driving speed, working angle, amperage, and there's a lot of room for that. However, in laser welding where good path accuracy is critical, there are other factors to consider.

The tenacity of conventional laser welding

Aside from personal opinion and applications, there is also the reality that laser systems tend to be more expensive than his traditional MIG or TIG systems (although costs have dropped).

There is also the maintenance cost of the laser processing head. For example, a laser unit must be surrounded by a "tight" space, while MIG and TIG systems can often be inexpensively shielded using only metal plates.

Affordability and setup comparable to traditional welding systems make traditional welding system setups more attractive. However, in the long run, laser systems are often more cost-effective in terms of throughput and cost per part. Laser systems are partly a cultural barrier and partly an economic barrier. When it comes to soldering, preference is usually given to the most vetted, mature, well-understood, and least expensive systems. So there is still a lot of room for traditional welding methods in today's industry.

Advantages of laser welding

Although laser welding is somewhat more expensive, it will undoubtedly increase productivity and reduce costs in the long run. Relatively speaking, laser welding is still a 'beginner' compared to the more established traditional welding methods. Although somewhat expensive, laser welding is sure to improve productivity and reduce long-term costs for any job using it.

Laser welding systems can weld consistently and much faster than other methods. In some cases, it is ten times faster than TIG welding and five times faster than MIG welding. In sheet metal processing, laser welding is unmatched. The low heat input is especially suitable for automatic welding of sheet metal as it prevents the burn-through of thin materials where the laser is less accurate.

In fact, laser welding offers a good option for nearly all parts that are normally TIG welded, and often MIG welded. Laser welding does not require shielding gases or filler metals. Due to its inherently low profile, no grinding is required after welding is complete. For example, a common use of sheet metal is his MIG manufacturing method for the manufacture of electrical boxes. Outside corners usually need to be sanded after manufacturing.

All this saves time, effort and money, making the whole process cost effective and productive.

Two laser system modes and their applications

Laser systems generally have two modes of his: the “conduction” mode and the “keyhole” mode. Depending on your operation, these modes can be very useful.

Conduction mode is a low energy density laser system. The laser here usually has a large spot and gently heats the surface of the material to transfer thermal energy. Same as TIG welding, it is suitable for precise surface welding. Application examples: Creating outer corners of boxes and signboards.

Keyhole mode is a high energy density laser. Here, the laser actually penetrates two layers of material (one stacked on top of the other), evaporates the top material, then penetrates the bottom, and at incredibly high speeds. Both layers can be filled. In fact, the laser system is much more efficient than spot welding as it only needs to touch his one surface of the stacked material and requires less automation.

Spot welding is commonly used to weld car bodies in the automotive industry. This is the last of three common conventional methods that are most likely to be replaced as laser welding advances.

So is laser welding the right choice for your job?

As with most things in life, the answer is not that simple.Laser welding is definitely more efficient and cost-effective than traditional methods, saving you money, time and effort in the long run. The biggest obstacle to doing so is the mature method, which is currently prevailing.

Focusing on fillet welding, there are some operations that MIG can "do" well, but for many others, especially his TIG and spot welding applications, taking over the laser system is not only desirable, but inevitable. should be considered. It will continue to decline and laser systems will gain a bigger foothold in the wider industry.