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LASER WELDING

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Nonconventional Technologies Review – no. 4/2009

 
LASER WELDING

Cristian CORBA, Peti FERENCZ, Ioan MIHĂILĂ

Abstract : One of the newest procedures successfully used in machine building industry, fine mechanics,
electronics, aeronautics, is based on AMPLIFICATION BY STIMULATED LIGHT EMISION OF RADIATON.
Laser Welding claims the laser beam to focus greater energy in a space point, melting and welding parts
such as material creating a very stable and resistant junction between these. Sent energy to spare is focused
specifically on the joints, so that the heat affected zone and thermal distortions are minimal.

 
KEYWORDS: laser welding, welding, laser.

1. INTRODUCTION Consequently, for applying thermal

energy to small areas, there are no other
The welding is to conduct an operation of methods as efficient as lasers are. This ability
unremovable metal joints using local heating, to selectively apply energy offers some

pressure or both, together or not with the use
of added metal similar to metal parts
combined.
The totality of technological operations used
in a certain kind of welding is a welding
process. The combined result by applying
the welding process is called welding.
All welding processes can be divided into
two large groups:
distinctive metallurgical advantages in some
welding applications, but also creates some
unique problems. Since the surface heating
generated by the laser light relies upon the
material's heat conductivity to produce the
weld, penetration is usually limited to less
than 2 millimeters.²
2. PROCESS PRINCIPLES

• welding processes with melting
• welding processes with pressure.
By welding processes with melting, the
edges of welded parts are transformed in
liquid by local heating, with or without added
metal.
By welding process with pressure, the
combination is obtained under the action of
the forces transmitted by pressing parts
Generally, there are two types of lasers
that are being used for welding operation:
CO2 and Nd:YAG.
Components of the NMGRL CO2 laser
system (fig.1).
1. Color CCTV camera (Polnux TMC-574)
2. Optical lens

 
welded, with or without local heating them. 3. IR transparent optical mirror
Laser welding of metals is one of the 4. Vibration isolated workstation/table
welding processes by melting. Laser welding (Newport Corporation)
is applied in all welding positions: but 5. Automated stage:
welding, overlap welding and corner welding. 6. Sample chamber: base = 3.375" flange;
Welding results when materials are heated to window = ISI ZnSe 1.5 window mounted
a molten state and fused together. Lasers in 3.375" flange
generate light energy that can be absorbed 7. Copper sample holder; 6 to 221 sample
pits

into materials and converted to heat energy.
By employing a light beam in the visible or
infrared portion of the electromagnetic
spectrum, we can transmit this energy from
its source to the material using delivery optics
which can focus and direct the energy to a
very small, precise point. Since the laser
emits coherent radiation, energy beam has
minimal divergence and can travel large
distances without significant loss of beam
quality or energy.
34
8. Potassium bromide cover slip: 2mm thick
x 38.1 mm diameter
9. first surface silicon mirror
10. 1" diameter by 5" focal length ZnSe
meniscus lens, II-VI #376587
11. Beam integrator lens
12. Laser power meter head; Molectron
PM150-19-C, swings in or out of beam
path to measure beam intensity
13. Laser feedback diode, Synrad CA-48-CL
14. 50-watt CO2 laser, Synrad 48-1-28W
 
  
Nonconventional Technologies Review – no. 4/2009

 
15. He-Ne pointer laser, Synrad He-Ne 18. CO2 laser controller with 0-10 volt DC
16. Two-axis motion controller with IEEE.488 input, Synrad UC-1000
communications, Newport PMC200-P 19. 0-40 volt, 10 amp power supply with 0-10
17. Laser power meter, Powermax 5100 volt input

 
 
 
(fig.2)
Fig.1. NMGRL CO2 laser system.

Components of the Nd:YAG laser system 3. WELDING CALCULATIONS

Knowing the size of the focused spot is

helpful in calculating energy density at the
work surface. For a fundamental mode

 
(TEM00) beam:
S = ( 4l / p ) × ( F / D)
S = Focused Spot Diameter
l = Laser Wavelength
F = Focal Length of Objective Lens
D = Diameter of Laser Beam
For a multimode beam:
S=F×f
where:

 
F = Focal Length of Objective Lens
M = Laser Beam Divergence

4. CONCLUSION

Generally, laser welding does not require

added material. In some situations,
Fig.2. Nd:YAG laser system. metallurgical reasons (some types of
aluminum), or in case of imperfect surfaces
that require the addition may be used and
added material. Laser welded joints are very
35 
 
  
Nonconventional Technologies Review – no. 4/2009

thin and can be finished (cleaned / ground)
welds obtained more easily than other
technologies.
Advantages
The advantages of laser welding
compared to conventional welding techniques
(TIG/MIG, spot welding) are:
• Little deformation
Process can be automated well
• Profitable construction possibilities
• Higher solidity at little seam volume
• Thin seam geometry
• Welding in places that cannot be
accessed easily
• Weld accessibility from 1 side suffices
• Strong construction with high fatigue
resistance

• No additional material needed
• Little or no post-processing
• Cost-cutting
• Retains corrosion resistance
• Possibility for weight reduction
• High welding speed achievable
• Welding of strongly magnetic material
is possible
• Fluid- and gas-tight connections can
be realised without adding materials
such as kit.

Table 1. Advantages of Laser Welding Compared to Other Processes

Competing Process Advantages of Laser Welding

 
• Faster welding rates by an order of magnitude; low distortion;
• Gas Metal Arc
no filler metal required; single-pass two-side welding
• Submerged Arc • Faster welding rates; low distortion; no flux or filler needed
• Resistance • Non-contact, eliminating any debris buildup; can reach
Welding otherwise inaccessible locations; faster welding rates
• Does not need to be performed in a vacuum; on-line
• Electron Beam processing; shorter cycles and higher uptimes; welds magnetic
materials; does not require radiation shielding

 
Laser welding tolerances

 
 
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Nonconventional Technologies Review – no. 4/2009

REFERENCES

 
[1] Mihaila I.: Tehnologii neconventionale .
Oradea. Edituta univesitatii din Oradea
[2] Miller C.: Laser Welding Article. U.S. Laser
Corporation
[3] DataConsult: Masini de sudat cu laser 3D-
www.data-consult.ro(accesed 03/11/2009)
[4] Demar Laser: Laser welding: -
www.demarlaser.nl-(accesed 15/11/2009)

Romania
 AUTHORS

Prof.PhD.eng. Mihaila I., University of Oradea,

Phd. Student Corba Cristian, University of

Oradea, Romania, cristicorba@yahoo.com 0743
/183 599
Phd.Student Ferencz Peti, University “Petru

 
Maior” Târgu Mures, petiferencz82@yahoo.com
04740/289436

 
 
 
37 
 
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