Industrial applications and benefits of laser welding

Introduction

Welding is a fundamental process in industry that allows the permanent joining of materials, especially metals, by means of different methods, each with specific applications according to the requirements of strength, precision, and type of material. Among these techniques is laser welding, which stands out for its precision and ability to fuse parts with great accuracy.

Characterized by the ability to transfer energy in the form of heat, laser welding generates a weld pool that, when cooled, creates a solid joint. This article examines in detail the operation, types, and advantages of this process.

What is laser welding?

Laser welding is an advanced fusion joining process that uses a high-intensity laser beam to melt and join materials, primarily metals and thermoplastics. The laser beam, focused on a precise area, transfers energy in the form of heat, creating a bath of molten material that, when solidified, forms a strong, robust bond. This process can be performed with or without filler material and is ideal for generating precise, narrow, or deep seams, depending on the configuration.

One of its great advantages is its ability to work with diverse materials, including reflective metals and combinations of dissimilar materials, with minimal thermal distortion. In addition, the process enables high welding speeds, optimizing production in high-precision industrial applications such as automotive, aerospace, medical manufacturing, and precision jewelry.

This process can be easily automated, increasing efficiency, or performed manually with specialized tools, achieving precise control over weld quality in complex applications.

Working principle of laser welding

Laser welding is based on the generation of a high-intensity laser beam that is precisely focused on the joint of the materials to be welded. Through an optical system, such as a collimator or a focusing head, the laser concentrates its energy in a small area, generating a localized heat build-up. This heat melts the edges of the materials, creating a melt pool that, when solidified, forms a robust bond.

The use of such a concentrated beam allows welds to be made with high precision and speed on thin materials, and deep, narrow welds on thicker materials, without affecting surrounding areas². The ability to control heat input ensures efficient melting with minimal deformation.

Laser types in welding

• CO₂ (carbon dioxide) lasers: They are widely used in industrial welding due to their high power output and their ability to weld a variety of materials. They operate in the mid-infrared range, where they excite carbon dioxide molecules, generating a focused laser beam that allows deep penetration welding with high precision. They are ideal for processes that require high speed and productivity. However, their efficiency with reflective metals such as stainless steel and titanium can be limited, and they require gas assistance, which increases their operating costs. Despite these limitations, their versatility and accuracy make them suitable for a wide range of industrial applications.
• Nd lasers (neodymium-doped yttrium aluminum garnet): These are solid-state devices that emit high-power infrared light with a wavelength of 1.064 micrometers, which allows excellent absorption by metals, especially aluminum, stainless steel, and titanium alloys³. This feature makes Nd lasers ideal for applications in industries such as automotive and aerospace, where precision and robustness are critical.
• Fiber lasers: They stand out for their high energy efficiency and excellent beam quality. The energy generated by the laser diode is transmitted through an optical fiber to the welding point, allowing a precise and controlled application. These lasers are ideal for automation in industrial processes, as they are easily integrated into automated equipment and offer a long service life with low maintenance costs.
• Disk lasers: These are a variant of solid-state lasers in which the laser medium is a thin disk of semiconductor material doped with elements such as yttrium or yttrium-aluminum. These lasers are liquid-cooled and enable the emission of high-quality laser light. Thanks to their low maintenance requirements and long service life, disk lasers are widely used in industrial applications requiring high power capability and a high level of welding precision.

Benefits of laser welding

Greater precision and control

Its ability to focus an extremely narrow beam on tiny areas, even as small as millimeters in diameter, enables high precision when making intricate and detailed welds, optimizing process control. Precisely controlling the beam energy minimizes the heat-affected zone, reducing part distortion and material waste. In addition, this high level of precision guarantees consistent joint quality, avoiding errors and ensuring more efficient use of resources in every weld made.

Speed and efficiency

Laser welding speeds up production processes, making it a more competitive option compared to traditional welding. Despite a higher initial investment, this method offers considerably faster processing times, which increases productivity. The laser beam concentrates the energy precisely, melting the material almost instantly.

This rapid heat build-up allows welding to proceed at an accelerated rate, minimizing thermal spread and reducing the time required to complete the task. This results in increased throughput and optimized turnaround times, improving the overall performance of industrial operations.

Flexibility in welding different materials

This type of welding offers a notable advantage in joining dissimilar materials, since it allows fusing components of different chemical compositions and thermal properties with precision and minimum distortion. This feature is essential in industries where the integration of metals such as steel and aluminum, or copper and titanium, requires meticulous control of temperature and applied energy.

The flexibility of laser welding to adapt to various materials is due to its high-precision targeting and parameter control capabilities, allowing it to create strong, homogeneous joints even in materials that tend to be highly reflective or highly conductive. This capability reduces defects and improves the quality of multilayer assemblies, optimizing both the durability and performance of end products in demanding applications.

Industrial laser welding applications

Automotive industry

This technology enables the manufacture of lighter and more compact assemblies by using thin walls and controlling heat input, which optimizes vehicle weight without compromising structural strength. In addition, laser welding in car bodies improves torsional rigidity and enables more flexible joints, such as in multilayer assemblies or parts of different thicknesses, which increases component performance and durability.

The welding of “tailored blanks”, parts of different thicknesses and materials joined with lasers, has gained popularity for reducing production costs and improving material efficiency, thus meeting the strength and weight reduction requirements of today’s vehicles.

Aerospace industry

Laser welding in the aerospace industry represents an indispensable factor in achieving exceptional levels of precision and reliability in the manufacture of critical components. The need for maximum performance in aerospace parts and airport security systems makes this technique a superior choice, as it enables compliance with rigorous industry standards. Its implementation ensures high strength and durability joints, minimizing thermal stress on the surrounding material, which significantly reduces imperfections and prevents alterations in material properties.

In addition, it is a technology that is less invasive than conventional methods and allows welding of dissimilar materials, which is advantageous in the construction of complex, lightweight components. The precision and consistency offered by laser welding ensure optimum performance, which is essential for maintaining safety and effectiveness in aerospace applications.

Medical industry

As medical equipment shrinks in size, the laser becomes an ideal tool for creating tiny welds in complex areas, creating sterilized surfaces without the need for post-treatment. As a non-contact process, laser welding minimizes thermal damage to the surrounding material, which is crucial for preserving the integrity of delicate medical devices.

In addition, the high precision of laser welding ensures a fast and cost-effective process without compromising quality. This method also makes it possible to weld different metals without adding filler materials, eliminating potential biocompatibility problems in products such as implants. Examples of medical devices produced by laser welding include pacemakers, hearing aids, prostheses, and catheters.

Conclusion

The need for increasingly precise welds is driving the use of laser welding in modern industry. This process, which allows careful heat control and minimal distortion, is ideal for the manufacture of delicate and complex components. Its application in sectors such as automotive, aerospace, and medical responds to the high demands for quality and efficiency, optimizing both the use of materials and production times.

References

1. https://www.ipgphotonics.com/solutions/laser-materials-processing/laser-welding
2. https://esab.com/mx/nam_es/esab-university/blogs/what-is-laser-welding-and-how-does-the-technique-work/
3. https://www.trgsl.es/es/noticias/soldadura-laser/