It was developed as a result of ever evolving products and their need to be smaller and perform to a higher standard. Hybrid welding combines laser welding with other welding processes, typically MIG welding. 1、Due to the extremely small focused spot and the small heat-affected zone of the UV laser, ultra-precision marking and special material marking can be performed. (Association of German Laser Users – Sheet Metal Working) represents the interests of owners, managing directors and company executives in the wide materials processing market – in this case, of sheet metal. Their aim is to encourage cooperation for the benefit of all parties involved.
Power density is one of the most critical parameters in laser processing. Currently, the world ABB, FANUC, MOTOMAN, KUKA, etc. have laser applications. Laser composite welding technology does not act in sequence between the two welding methods, but rather both methods act on the weld zone simultaneously. The basic principle of laser-MIG composite welding is shown in Figure 4.
The laser output has no “inertia” and can be stopped and restarted at high speeds, making it possible to weld complex workpieces with CNC beam movement technology. This is especially necessary in high power laser welding, where the ejecta become very powerful. Nitrogen is the least expensive as a shielding gas, but it is not suitable for certain types of stainless steel welding, mainly due to metallurgical problems, such as absorption, which sometimes produces porosity in the lap zone. It is the most effective shielding gas used in laser welding but is more expensive.
Fiber laser system manufacturers, thus, have developed new hardware that makes new product applications possible. Each of these welding processes have multiple practical uses within the manufacturing industry. In the hands of the right professional, the technology can help create customized pieces for various applications. Thus, heat conduction welding is used mostly to join parts with thin walls. The laser produces a smooth, rounded seam that does not require any extra grinding or finishing.
With its low machine-hour rate, it really comes into its own for small to medium lot sizes and for when components are changed frequently throughout the day. With large spot, the plastic at the joint is evenly melted, to create strong welding and perfect sealing. In this example of a patchwork design, one combination head cuts and welds the workpiece.Another example is the patchwork design in Figure 5. The integrated cutting and welding process chain opens up the cost-efficient production of new designs. In standard cutting heads, an intense cutting gas flow, traveling coaxially to the focused laser beam, has to provide for effective melt ejection out of the kerf. A high-pressure nozzle guides the laser beam in such a way that the beam focus and the gas jet meet the workpiece below the nozzle exit.
The power density is less than 104~105 W/cm2 for thermal conduction welding, when the melt depth is shallow and the welding speed is slow. The melt pool of laser-MIG composite welding is smaller than that of MIG welding, resulting in low heat input, a small heat-affected zone and low workpiece distortion, which greatly reduces the work of correcting weld distortion after welding. The biggest advantage of laser remote welding over conventional welding is increased productivity. The laser remote welding system is highly flexible and efficient, and one system can replace 6 to 9 sets of ordinary robotic spot welding. The motion system, which realizes the travel of the welding trajectory, also carries the laser brazing head and ancillary devices, water and gas circuits, etc. The wire feeding system is responsible for stable wire feeding during welding.
Any material with a high heat conductivity can be laser welded, whether it’s for an automobile or a small medical/jewelry item. Laser welding is also frequently used in high capacity manufacturing in the medical and automotive industries. Laser welding utilizes a laser beam as a concentrated heat source to join multiple pieces together.
It guides the arm to the intended points and regulates the duration and intensity of the laser beam. The process of additive manufacturing, which has started to spread almost 10 years ago, is currently reaching its peak with laser welding. For a long time, 3D printing was only available for ceramics and plastics.
Although laser welding gained popularity in 3D printing, it has now also become useful for automated versions of more traditional welding applications. A laser is merely a highly concentrated beam of light that delivers a vast amount of power. The high power density of lasers allows them to melt the material of the workpiece in a controlled manner. By subjecting the material to a high-powered laser beam, the molecules in its surface gain enough energy to get excited and gain more fluid-like properties. Deep penetration welding requires extremely high power densities to create a laser weld.
Hybrid Laser GMAW welding is an automated, high performance welding process which results in a very narrow heat-affected zone with deep penetration and high travel speeds relative to traditional processes. This breakthrough approach combines the highly focused intensity of a laser with the joint filling capability of the traditional MIG process. By combining the two, hybrid laser welding provides a unique opportunity for thicker welds with less filler metal or higher travel speeds than typical welding, depending on the material thickness. Depending on a TIG welder’s skill level, the bead path can include peaks and valleys. Conversely, pulsed laser welding enables users to start and stop the operation at precise positions while depositing a more consistent bead height.
Glass or plastic, for example, cannot be joined at all by any other process. The costs are still the biggest disadvantage of these innovative processes. It depends strongly on what and which material is to be processed with the laser welding system.
Leister’s innovative laser systems open up new possibilities in the automotive, medical, sensors, electronics and micro-system technology industries for plastic joining. We specialize in finding customized, cost-effective solutions ranging from common joining problems to the most critical and complex customer demands. As an example, Leister’s patented and award-winning GLOBO Optic is an exclusive technology module that can weld three-dimensions plastic components in a single step to eliminate the complex tooling requirements of other joining technologies. In addition to our laser technologies, our highly-trained specialists can assist in the design and component construction, material selection, process optimization and equipment integration for new and existing manufacturing platforms. Leister Technologies has been a global leading provider of plastic welding equipment for over 70 years. With comprehensive theoretical and practical knowledge in a wide range of plastics processing techniques, Leister is able to confidently apply multi-faceted, “big picture” solutions with ease.