For companies looking to improve the productivity of their products and reduce the costs of their welding operations, then laser welders should be considered. Laser welding is more convenient and less expensive than ever, providing faster turnaround time than other welding and soldering techniques similar to those used in welding equipment.
Finding ways to improve productivity and reduce costs is essential in any welding application. Although most companies think about advancing technology to achieve these goals, many jobs will not consider laser welding. You may think it’s too expensive or too difficult.
Advances in laser welding technology have made it more usable and cheaper than ever. These processes also have significant commercial product benefits that can provide a quick return on investment. It is particularly suitable for sheet metal welding applications. Is laser welding suitable for sheet metal work? Think about these important things and their benefits.
The advantages of laser welding
Laser welding offers 5-10 times faster turnaround than TIG welding and 3-5 times faster than MIG welding in some applications. It is also an excellent alternative to spot welding in a variety of applications. Automatic sheet metal welding is an example where the transition to laser welding can provide significant results. Since laser welding techniques offer high latency and low power consumption, they often help prevent burns in thin materials.
There are also prefabricated laser welding machines on the market that are easy to install, reducing downtime for lighting. The use of laser welding continues to grow in the use of laser welding technology due to advances that have made the equipment more practical and economical. Laser welding uses a laser to join metals. Traditionally, powerful lasers used carbon dioxide as a medium and had a wavelength of up to 10 microns. Lasers of this wavelength cannot be transmitted through fiber optic cables, making it difficult to automate the laser welding process.
The use of technology has increased the market share in this regard. Advances in 1 micron wavelength lasers mean that lasers can be transmitted over fiber optic cables, making it easier to automate lasers for welding. Also, 1 micron wavelength lasers are usually diode driven. As manufacturers have become more aware of robust diode design, fewer diodes are needed for power lasers. This permanently reduces the unit cost of the laser welding machine.
Products that have historically been TIG welded and require a good machined surface are good competitors for transitioning to the laser welding process. These factors make laser welding particularly suitable for metal applications. Sheet metals are generally thinner and require less electricity when welding. They are also frequently used in applications requiring aesthetics or aesthetic benefits, such as electrical appliances, signage, or elevator panels. Laser welding can be a good solution for these needs.
In addition, laser welding sometimes does not require the use of metal fillers or oil guards. This provides a minimal profile which eliminates the need for grinding after welding is complete, saving time and money and making the production process easier. For example, a metal application is typically an electrical enclosure manufacturer. MIG welding generally requires grinding after welding to remove excess weld from the outside edges. Switching to laser welding eliminates the time and cost of cleaning up after welding.
And, as mentioned earlier, the speed of laser welding compared to TIG or MIG welding helps companies improve the productivity and efficiency of their products, which can positively impact their bottom line. There are two types of laser welding: conduction and keyhole. Each type is ideal for special applications, so you should think about which one best suits your needs.
When the energy is lower, the laser has more surface area and less energy. Types of leadership. In this mode, the surface is heated and the heat is transmitted partly by conduction. Most conventional designs have a finish similar to a T-weld and are well suited for external welds that need to be machined, such as the outside corners of the box or plates.
The keyhole type can be used to drill two pieces of joining material on top of each other to create welds. When the laser light hits the surface, it vaporizes, piercing both parts and filling the weld as the laser moves. This makes keyhole type laser welding a good alternative for stacked or layered materials that previously required processing, such as spot welding. Keyhole type laser welding is much better than spot welding, which uses two electrodes and requires penetration from the top and bottom of the welded material. Resistance welding sites are also more difficult to automate.
The same laser welding machine can be used for both conduction mode and keyhole type. Increasing the power or decreasing the area of a small laser changes mode by conduction to the keyhole. The use of prefabricated laser welding technology offers many advantages. The prefabricated systems available on the market are easy to use, quick and easy to install.
Some pre-assembled cells can be mounted on a single platform and delivered pre-assembled so they can be placed into solder and usually quickly and run the same day. The laser welding cell can be as simple in position as any other welding machine. The main difference between the pre-engineered laser welding machine and another pre-engineered robot machine is that any light in the welding area of the laser system must be included in the device for safety reasons. . When all the light is present in the welding cell, the laser welding system is Class 1. This means that workers outside the cell do not need additional eye protection. This provides an easier way that a laser welding machine can be placed in a home store or on the floor of a house.
Some welding machine companies also have labs that can make model laser welding machines. This will help you determine if the laser machine is suitable for your application. Significant increase in productivity
Laser welding is an unknown or unexplored option for many companies using welding technology, but it is as easy to use as other welding machines. The high speed and low heat dissipation of laser welding make it specially designed for sheet metal welding applications that require special attention to accuracy and precision.