Are you looking forward to DIY laser welder kit plans or coming up with an idea to buy an affordable robotic or handheld laser welding machine for miniature, densely arranged, precise, and heat-sensitive parts with jewelry, kitchenware, aerospace, automotive, electronic devices and components, commercial, shipbuilding, chemical & medical industries to realize spot welding, butt welding, stitch welding, and sealing welding in USA, UK, UAE, Canada, Australia, Russia, South Africa, China, India or other countries from Asia, Europe, North America, South America, Africa, and Oceania?
Review the 2022 best laser welder buyer's guide for machinists, operators and beginners, we'll offer you 2022 cheap fiber laser welding machines with 1000W, 1500W, or 2000W laser power, and expert laser welding service to fit your custom laser beam welding plans, projects, and ideas.
Laser welding machine is an eco-friendly power welding tool with handheld laser welding gun, CNC controller, or single-arm robot to join pieces of metals or thermoplastics.
Laser beam provides a concentrated heat source, which is used for spot welding, butt joint, lap joint, lap edge, lap, T butt, seam welding, narrow welds, deep welds, and kissing weld with high welding rates.
The process is frequently used in high volume applications with automation, which is based on keyhole or penetration mode welding.
Laser welding machines are engine driven welders used for a variety of applications from welding very small parts together commonly used by manufacturing businesses in the engineering, medical and electronics industries, through to welding thicker materials in the automotive and aerospace industries.
Laser welding is a versatile, low cost way of achieving high quality spot welds for different materials and thicknesses.
A laser welding machine is also known as laser beam welding machine, laser welder, laser beam welder, laser welder machine, laser beam welding equipment, laser beam welding gun, laser beam welding tool, seam welding machine, laser bonding machine, laser brazing machine, laser joining machine, laser soldering machine.
Laser Beam Welding (LBW) is a new type of fusion welding method that radiate a high-intensity laser beam to the surface of the material, and the material is melted to form welding through the interaction of the laser beam and the materials.
It uses the principle of atomic stimulated radiation to stimulate the working substance (laser material) to produce a laser beam with good monochromaticity, strong directionality and high intensity.
The highest energy density of the focused laser beam can reach 1013w/cm2, which converts light energy into heat energy in a few thousandths of a second or less, and the temperature can reach more than 10,000 degrees Celsius.
The high-heat laser beam raises the local temperature of the material, and the energy generated by the laser diffuses into the material through thermal conduction, melting the material to form a specific molten pool, so as to achieve the purpose. Laser welding is mainly used for the welding of thin materials and precision parts.
Laser welding is a process that uses the radiant energy of the laser to achieve effective welds. Its working principle is to excite the laser active medium (Fiber, CO2, YAG) in a specific way, so that it oscillates back and forth in the resonant cavity, thereby forming stimulated radiation When the beam is in contact with the workpiece, its energy is absorbed by the workpiece, and welding can be performed when the temperature reaches the melting point of the material.
A good rule of thumb is that entry level portable handheld laser welders will sell for a price range from $5,800.00 to $10,500.00 with fiber laser powers of 1000W, 1500W, and 2000W.
The best budget automated CNC laser welding systems cost from $18,800.00 to $25,800.00 with fiber laser powers of 1000W, 1500W, and 2000W.
The affordable automatic robotic laser welding machines will be priced from $48,000.00 to $58,000.00 with fiber laser power supply of 1000W, 1500W, and 2000W.
The cheapest 3-in-1 laser welding, cleaning, cutting machine costs from $5,500.00 to $7,500.00 with fiber laser power supply of 1000W and 1500W.
The average cost for laser beam welding machines is about $7,800.00 for handheld types and $52,800.00 for robot types in 2022.
However, costs vary widely depending on the welder's configurations & features.
|Laser Power||1000W, 1500W, 2000W|
|Laser Source||Fiber Laser|
|Cooling System||Industrial Water Chiller|
|Price Range||$5,500.00 - $58,000.00|
Laser welding results across a wide range of materials. There are three common types, including CO2 laser, YAG laser, and fiber laser welding. There are high-power welders for large-format and thick sheets, and low-power welders for small-size parts. There are welders for metals and non-metallic materials such as plastics and ceramics.
Different methods can be classified as follows:
1. Welds between slices. Including butt welds, end welds, center penetration fusion welds, and center perforation fusion welds.
2. Wire and wire welds. Including wire-to-wire butt welds, cross welds, parallel lap welds, and T-type welds.
3. Welds of metal wires and block components. Laser beam welding can successfully realize the connection between the metal wire and the block element, and the size of the block element can be arbitrary. Attention should be paid to the geometric dimensions of the wire-like components during welding.
4. Welds of different metals. Welds different types of metals must solve the range of weldability parameters. Laser beam welding between different materials is only possible with certain material combinations.
Laser welders are widely used in manufacturing, shipbuilding industry, automotive industry, battery industry, aerospace industry, jewelry, biomedicine, powder metallurgy, electronics industry, IT industry, electronic devices, optical communication industry, sensor industry, hardware industry, automobile accessories industry, glasses industry, porcelain teeth, solar energy industry, electric heating industry and thin material, precision parts manufacturing.
It can realize spot, butt, stitch, and sealing welding, and consistent high quality results. Laser beam welding is especially suitable for miniature, densely arranged, precise, and heat-sensitive workpieces.
Taking automobile manufacturing as an example, laser beam welding has achieved large-scale, and related automatic production lines and welding robots have appeared.
According to relevant statistics, in developed industrial countries in Europe and America, 50% to 70% of auto parts are processed by laser processing. Among them, laser welding and laser cutting are mainly used, and now LBW is a standard process in automotive manufacturing.
Automobile industry has also begun to attach importance to this advanced welding technology. In the automotive industry, laser manufacturing technology is mainly used for body tailor and parts welding.
The laser used in the welding of car body panels can weld metal plates with different thicknesses and different surface coatings together, and then press them, so that the panel structure made can achieve the most reasonable metal combination. Since there is little deformation, secondary processing is also omitted. LBW speeds up the process of replacing forged parts with body stamped parts.
The use of LBW can reduce the overlap width and some strengthening parts, and can also compress the volume of the body structure itself. This alone can reduce the weight of the body by about 50kg. Moreover, LBW technology can ensure that the solder joints are connected to the molecular level, which effectively improves the rigidity and collision safety of the car body, and at the same time effectively reduces the noise in the car.
Laser tailor welding is in the design and manufacture of the car body. According to the different design and performance requirements of the car body, different specifications of steel plates are selected, and the manufacture of a certain part of the car body, such as the front windshield frame and the door inner panel, is completed through laser cutting and assembly technology.
Tailor-made laser beam welding has the advantages of reducing the number of parts and molds, reducing the number of spot welding, optimizing the amount of materials, reducing the weight of parts, reducing costs, and improving dimensional accuracy.
However, LBW is mainly used for the frame structure of the car body, such as the top cover and the side car body. The traditional welding method of resistance spot welding has been gradually replaced by laser beam welder.
With laser technology, the width of the joint surface between the workpiece connections can be reduced, which not only reduces the amount of plates used but also improves the rigidity of the car body. It has been adopted by some of the world's major automakers and leading parts suppliers that produce high-end cars.
In aircraft manufacturing, it is mainly used in the splicing of large aircraft skins and long trusses to ensure the contour tolerance of the aerodynamic surface. In addition, it is also widely used in the assembly of fuselage accessories, such as the wing box of ventral fins and flaps. Later, the LBW technology is used to complete the welding and splicing in three-dimensional space. Not only the product quality is good, the production efficiency is high, but the process reproducibility is good, and the weight reduction effect is obvious.
In the jewelry industry, LBW can satisfy aesthetics and welding between different materials. It has been widely used in gold and silver jewelry repair holes, spot welding holes, and welding inlays.
The cladding technology in LBW has become the main technology for mold repair. The aviation industry uses this technology to repair the heat-resistant and wear-resistant layer of aero-engine nickel-based turbine blades. Compared with other surface modification methods, laser cladding has fast heating speed, less heat input, minimal deformation, high bonding strength, low dilution rate, precise control of the thickness of the modified layer, good localization, good accessibility, high productivity.
Other industries such as mobile phone batteries, electronic components, sensors, clocks, precision machinery, and communications have introduced LBW technology.
Due to the high investment in equipment, laser beam welder is currently only used in high value-added fields. Even in these fields, LBW has not been fully utilized for a long time. However, with the development of new laser manufacturing technology and equipment, LBW is gradually squeezing into the "territory" occupied by traditional welding technology for a long time.
Laser welding features concentrated and controllable heating range, small deformation and high speed.
In order to help you make up your mind, let's compare laser beam welding with arc welding.
The diameter of the laser spot can be precisely controlled. Usually, the diameter of the spot irradiated on the surface of the material is in the range of 0.2-0.6mm, and the closer to the center of the spot, the higher the energy (the energy decays exponentially from the center to the edge, that is, Gaussian distribution). The seam width can be controlled below 2mm.
However, the arc width of arc welding cannot be precisely controlled and is much larger than the diameter of the laser spot, and the width of the seam of arc welding is also much larger than that of laser, usually more than 6mm. Because the energy of laser is very concentrated, less material is melted, and the total heat required is small, so the welding deformation is small and the speed is fast.
Writing can be used as a metaphor for laser and arc. Laser beam welding is like writing with a 0.3mm signature pen. The words must be so thin and fast, and the paper is basically unchanged after writing. It can be said that it refers to where to hit.
Arc welding is like writing with a large brush Not only is it thick, but the thickness of the characters varies with the force used, and the writing is slow. After writing, the paper is inevitably deformed due to too much water soaking.
Laser Deposit Welds
Repair and modification with reconditioned quality.
Spot & Seam Welds
From smallest welding spots to continuous seams.
No time loss by movement of workpieces or processing heads.
Flexible method for high strength connections with perfect surfaces.
Tube & Profile Welds
Optimal laser beam welding of tubes and profiles.
Laser beam welding is a heat conduction process. The surface of the workpiece is heated by laser radiation, and the laser energy is controlled to be highly concentrated in a certain small range of spot.
The surface heat is diffused to the inside through heat conduction, and the width, energy, peak power and repetition frequency of the laser pulse are controlled by parameters to melt the workpiece and form a specific molten pool.
Compared with traditional argon arc welding, laser beam welding has a natural advantage and is widely used in the fields of industrial electronics, automobile manufacturing and aerospace and other precision mechanical parts.
1. Since the focused laser beam has a much higher power density than the conventional method with times faster speed, and the heat-affected zone and deformation are smaller.
2. Because the laser beam is easy to transmit and control, and there is no need to change the torch and nozzle frequently, it significantly reduces the auxiliary time of shutdown, so the load factor and production efficiency are high.
3. Due to the purification effect and high cooling rate, the seam is strong and the overall performance is high.
4. Due to the low balance heat input and high processing accuracy, reprocessing costs can be reduced. In addition, the moving cost of LBW is relatively low, which can reduce production costs.
5. It is easy to realize automation, and can effectively control the beam intensity and fine positioning.
6. Minimum heat input. The melting process is completed quickly at high temperatures, resulting in extremely low heat in the workpiece, and almost no thermal deformation and heat-affected areas.
7. The energy density is large and the release is extremely rapid. It can avoid thermal damage and deformation during high-speed processing, and can process precision parts and heat-sensitive materials.
8. The material to be welded is not easy to be oxidized and can be welded in the atmosphere without gas protection or vacuum environment.
9. The laser can directly weld insulating materials, and it is easier to weld dissimilar metal materials, and can even weld metal and non-metal together.
10. The laser beam welding machine does not need to be in contact with the workpiece to be welded. The laser beam can be bent or focused in any direction with a mirror or a deflection prism, and it can also be guided to hard-to-reach places for welding with optical fibers. The laser can also be focused through transparent materials, so it can weld joints that are difficult to access by normal methods or joints that cannot be placed, such as electrodes in vacuum tubes.
11. The laser beam will not bring any wear and tear, and can work stably for a long time.
Laser-TIG Hybrid Welding
The features of laser and TIG hybrid welding are:
1. Using the arc to enhance the laser effect, the low-power laser can be used instead of the high-power laser to weld metal materials.
2. High-speed is possible when welding thin parts.
3. It can increase the penetration depth, improve the weld formation, and obtain high-quality welded joints.
4. It can ease the precision requirements of the base metal end face interface.
For example, when the CO2 laser power is 0.8KW, the current of the TIG arc is 90A, and the speed is 2m/min, it can be equivalent to the capacity of a 5KW CO2 laser welding machine. When the speed is 0.5 - 5m/min, the penetration depth obtained is 1.3 to 1.6 times that of the 5KW CO2 laser beam welding alone.
Laser-Plasma ARC Hybrid Welding
Laser plasma hybrid welding adopts coaxial method. The plasma arc is generated by a ring-shaped electrode, and the laser beam passes through the middle of the plasma arc.
The plasma arc has two main functions: on the one hand, it provides additional energy for laser, which increases the speed, thereby improving the efficiency of the entire process.
On the one hand, the plasma arc surrounds the laser, which can produce the effect of heat treatment, prolong the cooling time, reduce the sensitivity of hardening and residual stress, and improve the microstructural properties of the weld.
Laser-MIG Hybrid Welding
In addition to the energy input of the arc to the weld zone, the laser also delivers heat to the weld metal. The laser hybrid welding technology is not two methods acting in sequence, but two methods acting on the area at the same time.
Laser and arc affect the performance of hybrid welding to varying degrees and forms. During laser-MIG hybrid welding, volatilization occurs not only on the surface of the workpiece, but also on the filler wire, causing more metal to volatilize, thereby making the laser energy transfer easier.
MIG welding is characterized by low power cost, good weld bridging, good arc stability, and ease of weld structure improvement with filler metal. The features of laser beam welding are large penetration, high speed, low heat input, and narrow weld seam, but thicker materials requires a higher power laser.
At the same time, the molten pool of laser hybrid welding is smaller than that of MIG welding, and the deformation of the workpiece is small, which greatly reduces the work of correcting deformation after welding.
Laser-MIG hybrid welding produces two separate molten pools, and the heat input by the subsequent arc also acts as a post-weld tempering treatment, reducing the hardness of the weld (especially the welded steel). Due to the high speed of laser hybrid welding, production time and production costs can be reduced.
Dual Laser Beam Welding
In the laser beam welding process, due to the high laser power density, the metal is rapidly heated, melted, and vaporized to generate high-temperature metal vapor. Under the continuous action of the high power density laser, it is easy to generate a plasma cloud, which not only reduces the absorption of the laser by the workpiece, but also makes the process unstable.
If the laser power density that continues to be irradiated is reduced after the larger deep penetration holes are formed, and the larger deep penetration holes that have already formed absorb more laser light, as a result, the effect of the laser on the metal vapor is reduced, and the plasma clouds can shrink or disappear.
Therefore, use a pulsed laser with a higher peak power and a continuous laser, or two pulsed lasers with large differences in pulse width, repetition frequency and peak power to perform compound welding on the workpiece.
During the process, the two lasers are used. Co-irradiate the workpiece to periodically form large deep penetration holes, and then stop the irradiation of a laser in a timely manner, which can make the plasma cloud small or disappear, improve the absorption and utilization of laser energy by the workpiece, increase the penetration, and improve the ability.
Laser hybrid welding combines the two methods, and it uses the advantages of each to obtain the best effect, higher speed and good seam bridging ability. It is one of the most advanced welding methods at present, realizing the perfect combination of high speed and good quality.
Laser hybrid welding technology is a brand new welding technology in the automotive industry, especially for assembly gap requirements that cannot be achieved or economically feasible with laser beam welding. It has a wide range of applications and high-efficiency characteristics, while reducing investment costs, shortening production time, saving production costs and improving productivity, with stronger competitiveness.
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