The development of laser technology has made traditional welding methods, such as MIG / MAG, MMA, or TIG, no longer play a significant role in metal processing. Laser welders are more precise, efficient, and flexible. Currently, we can distinguish three basic types of lasers - YAG, CO2, and fiber lasers. In industry, the latter are gaining increasing advantage, offering higher operating speeds and greater reliability than the other two types. They also have a wide spectrum of applications. They are used in aviation, automotive, sanitary equipment production, and food processing, among others.
How does a laser welder work?
The mechanism of a laser welder is based on melting the contact area using a laser beam in an inert gas shield. The ability to regulate the beam makes it easy to adapt to the material being processed. The high energy density of the beam allows for joining elements up to 25 mm. The joint zone is very narrow, and the deformation is so small that no additional mechanical processing is required after welding.
During welding, the laser beam passes to the welded object through a special system of shutters, mirrors, and optical elements. The light beam is focused in the welding area and is reflected. The ability to absorb the energy of the laser beam by the workpiece is very important because the effectiveness of welding depends on it.
The welding process can take place by creating a weld pool, or with full penetration of the joint in multiple layers or with a single pass, and also without additional material. The welding process itself depends significantly on the material. If thin sheets of low-carbon steel are being welded, there is no need to use weld pool protection. This is related to the short time and speed of the entire process.
Types of welders
Laser welding is currently displacing traditional welding methods. Different types of lasers are used in such devices - diode, YAG, and fiber optic. The latter is characterized by the greatest flexibility in terms of the range of weld dimensions. It also allows for high speeds of the entire process, which in turn is a result of the high ratio of penetration depth to power. However, individual models of laser welders with fiber optic lasers differ in many respects, which primarily determines their purpose and effectiveness when working on specific materials.
Device size
The welding process requires great precision. Laser welders can join elements of various sizes, including sheets of metal, pipes, or other structural elements with unusual shapes. The size of the device itself is important both for work comfort and welding efficiency. There are large machines that also have worktables. They have found their application primarily when working on larger elements. An alternative to them are compact, handheld laser welders with a closed housing. They take up much less space, and thanks to advanced technology, they have high working parameters. They therefore work well in both large and smaller industrial halls.
Welder power
This is one of the key parameters considered in the division of laser welders. The output power of the laser determines the purpose of the machine. For thicker and larger materials, welders with a power level of 3000W will be best. For joining thinner materials, welders with less power, e.g., 1000W, are dedicated.
Automatic wire feeder
It is an important part of the laser welder's equipment, responsible for moving the wire through the handle, which in turn translates into the possibility of feeding it to the welding site. In some devices, as is the case with the FANUCI 4.0 PRO GenX laser welder, the feeder is additionally integrated with the device's software. In this case, the device works with a fill of 0.8-2.0mm thickness in "push" or "pull" mode.
Control system
Laser welders also differ in control systems. Manufacturers most often offer dedicated software integrated with the devices. Operating systems are operated through a user panel. In technologically advanced machines, these are touch panels - intuitive and easy to use. It is important to pay attention to the possibilities of setting individual parameters. A useful function is also remembering previous settings, and even ready-made programs.
Technical parameters
Technical parameters determine the effectiveness of the laser welder's work under specific conditions. The basic ones include the output power of the laser, which is currently at a level from 1000W to 3000W. Devices also differ in electrical voltage; in the case of the laser welder FANUCI 4.0 PRO GenX, it is 230V or 380V. Power consumption increases proportionally to the output power of the laser and is 5KW (for 1000W), 7KW (for 1500W), 9KW (for 2000W), and 11KW (for 3000W), respectively.
Laser welders also have different welding speeds, with the lowest power being 0-160mm/s, while at the highest 0-215mm/s.
Welder components
Modern, technologically advanced FANUCI laser welders are characterized by versatility of work; they can be used for different types of materials, including even the most delicate ones. With their help, elements of different thickness and shape can be joined. The obtained welds are very durable and do not require further processing. We owe this primarily to the reliable components used in their production.
Laser source
The efficiency of the welder's work and the quality of the weld depend on it. Fiber technology laser sources are characterized by an intensity 100 times greater than that of a CO2 laser. The smaller focal point of the laser beam results in a high power density, which, combined with high absorption, positively affects the efficiency of joining materials. It is estimated that the lifespan of a fiber laser is about 100,000 hours, so it can work for up to 45 years. Moreover, it is an environmentally friendly technology and conducive to safe working conditions. Fiber lasers enable the welding of highly reflective materials, which makes them even more versatile and flexible.
Laser head
It consists of a nozzle, a protective glass drawer, a switch, an electric motor, a fiber optic cable, and a cooling and shielding gas line. FANUCI laser welders use a head equipped with an electric beam movement system, which allows for correcting material imperfections. It moves very precisely and enables welding at a speed 2-10 times faster than traditional heads used in handheld laser welders.
Automatic wire feeder
It plays a very important role in the operator's work. It allows for automatic wire feeding, taking into account the set parameters. It has been integrated with the software, which translates into even greater precision of work. The automatic wire feeder allows for working with a fill of 0.8-2.0mm thickness in "push" or "pull" mode, i.e., feeding the wire while simultaneously guiding the operator's hand.
Control system
It is responsible for operating the device and managing its work parameters. The operator can control the output power of the laser, the speed and width of scanning, as well as set the welding mode - continuous or modulated. A great advantage is the function of remembering the operating mode of the welder, so that the next time there is no need to reset the same parameters.
Filtration system
Fiber optic laser welders are equipped with a special welding extractor with a filter responsible for limiting the level of air pollution in the workplace. Moreover, the purified air can return to the workspace again. This solution aims to reduce losses associated with removing warm air outside the building, which takes place in the case of extractors without a filter. The PRO CleanAIR filter system automatically removes dust and vapors, which translates not only into a more human-friendly work environment but also a longer lifespan of the device.
Advantages of laser welders
Laser welders, especially fiber ones, are distinguished by work parameters that allow them to achieve above-average precision in joining materials. They also build their advantage over other welding methods in terms of safety and versatility, as well as effectiveness, which allows for the elimination of additional mechanical processing after the welding process is completed.
What aspects make fiber optic laser welders better than other devices with the same purpose?
- They generate less heat, which translates into a reduced risk of deformation and other defects. This is conditioned by lower thermal stresses.
- Thanks to the ability to regulate the size of the beam, they work well when joining thinner and more delicate materials.
- Welds do not require additional mechanical processing, which translates into shorter working time.
- The filtration system ensures that the device does not generate fumes harmful to the environment and humans. This promotes the creation of a safe working environment.
- The laser welder works at high speed, both with thin and thick materials. This translates into efficiency of material processing.
- The long lifespan of fiber lasers allows for generating greater savings. Such devices can actively work for 100,000 hours.
Applications of welders
Laser welders are used in many industries. They can be used to join large elements, as there is no need to transport the processed materials to the workstation. Laser welders are used, among others, in aviation and automotive industries. They are used to join elements in photovoltaic systems. Due to their precision, they have found their application in the production of medical equipment, including insulin pumps and pacemakers. They are also appreciated in the electronics industry and in the production of sanitary equipment. The welding process is also carried out in the furniture, construction, and finishing industries.
What to consider when choosing a welder?
When choosing a laser welder, you must primarily consider its ultimate purpose - whether it will be used to join small or large elements, thin or thick, on a smaller or larger scale. These factors determine the choice of a device with appropriate parameters that will allow for effective and efficient work. Which factors are key?
- Power of the welder - the greater it is, the better it will handle thicker and larger elements
- Software - the system operating the welder should be intuitive and at the same time prepared for integration with company systems
- Processed material - what materials the welder can work on, whether among them are highly reflective materials
- Cooling system - in modern FANUCI laser welders, the cooling agent is water, not air, which translates into more stable and smoother operation
- Filtration system - responsible for clean air and work with limited adverse impact on the natural environment
- After-sales support - modern fiber lasers are characterized by very high reliability. However, there are no machines that do not sometimes require repairs, especially with intensive use. It is therefore worth paying attention to service and after-sales support when purchasing a laser welder
Laser technology has revolutionized the metal processing industry. Joining materials has become more precise, faster, and more efficient. The possibility of automation has made man more of a supervisor of the entire process than its main executor. Laser welders certainly streamline the entire work, which applies not only to small plants but also to large enterprises that focus their activities mainly on metal processing.