Today, welding is an innovative assembly technique that is used in all areas. While the technique itself is widespread, some of its processes are as yet not so well known and underused. Laser welding falls into that category. In spite of its reputation as a complex process, it offers unparalleled advantages, in terms of both technique and costs.
Description
Examples
Our expertise
Training
Description
DescriptionExamplesOur expertiseTraining
Laser welding of metals
Using a laser beam to weld metals involves high energy density, giving rise to a capillary made up of molten material and metallic vapours. The thermal energy transferred to the core of the capillary generates a fine and penetrating bead. It solidifies instantly, providing metallic and metallurgical continuity.
Welding productivity increased by up to 800 %
Reproducible process
Reduction or even elimination of the time for straightening welded pieces
Overall reduction of production costs
Heterogeneous welding (multiple materials, case-hardened parts, carbonitrided parts etc.)
Metals are welded by means of an optical head (scan head etc.) coupled with a power laser.
Unlike other conventional welding processes, laser welding makes it possible to create a capillary made up of metal vapours, preceded by molten material. While welding, high energy density is transferred within the capillary, making it possible to obtain a very fine welding bead.
The molten material that makes up the welded seam solidifies instantly, allowing the metallurgical and mechanical assembly of parts. That assembly technique allows localised welding with very little deformation, and high accuracy.
transport (body work, stiffeners, casings, chassis, axles)
energy (heat exchangers, fuel rods and grilles)
medical engineering (prostheses, sensors, implants etc.)
Benefits
Welding productivity increased by up to 800 %
Reproducible process
Reduction or even elimination of the time for straightening welded pieces
Overall reduction of production costs
Mechanical resistance at least equivalent to that of the base metal
Reduction of welding consumables
Great freedom in the designing of parts
Advantages
Above all, the use of laser welding for metal parts improves productivity by reducing the time spent on welding and straightening the welded parts, and allows greater freedom in the designing of parts (simpler assemblies). Laser welding also helps make savings by reducing production costs and the materials consumed by the welding process. This welding method also has an effect on the quality of the assembly by offering mechanical strength that is at least equal to that of the base material, and by reducing the part deformation rate. Laser welding is also an excellent solution for joining subassemblies of dissimilar parts or treated parts (carbonitrided, case hardened etc.)
Welding of dissimilar materials (steel to cast iron, stainless steel to Inconel etc.)
Welding of precious materials
Welding close to delicate components
Welding time is reduced to a tenth
Reduced deformation of parts
Welding of parts with limited accessibility
Process that can be automated
Assembly with no filler metal
Examples of applications
Laser welding is used in different areas of business: mechanical engineering (pinions, tooling, housings), transport (body work, stiffeners, casings, chassis, axles), energy (heat exchangers, fuel rods and grilles).
The use of new laser technology along with a scan head makes it possible to make welds that are mechanically strong and sealed.
Advantages:
Smaller laser investment
Shorter cycle time
Full control over paths
Reduction of void ratio
Automotive
Laser welding of aluminium alloys
The use of new laser technology along with a scan head makes it possible to make welds that are mechanically strong and sealed.
Advantages:
Smaller laser investment
Shorter cycle time
Full control over paths
Reduction of void ratio
Laser welding of fine materials generates small welds at a high speed. Today, advancing laser technology makes it possible to weld highly reflective materials such as copper or aluminium.
Advantages
High production speed
Sealed weld
Heterogeneous assembly
Full control over the application of heat
Energy
Laser welding of cells and batteries
Laser welding of fine materials generates small welds at a high speed. Today, advancing laser technology makes it possible to weld highly reflective materials such as copper or aluminium.
Advantages
High production speed
Sealed weld
Heterogeneous assembly
Full control over the application of heat
Thanks to the precise management of laser welding parameters, small welds can be achieved even on highly reflective materials.
The high welding speed significantly reduces deformations, making it possible to weld watch movement parts.
Examples: welding of pins to sprocket wheels, rotors to pins, welding links and pins for watch straps, welding of precious metal appliqués on dials.
Advantages
Fineness of the weld metal zone < 100 µm
Mechanical strength
Very low deformation
Watchmaking-Jewellery
Laser welding of precious metals
Thanks to the precise management of laser welding parameters, small welds can be achieved even on highly reflective materials.
The high welding speed significantly reduces deformations, making it possible to weld watch movement parts.
Examples: welding of pins to sprocket wheels, rotors to pins, welding links and pins for watch straps, welding of precious metal appliqués on dials.
Advantages
Fineness of the weld metal zone < 100 µm
Mechanical strength
Very low deformation
The very low deformation due to the effect of the laser makes it possible to assemble finished parts such as components of gear boxes or cam shafts. Lasers also allow new assembly designs, for example to replace bolted assemblies in regulation components.
Advantages
Higher welding speed
Process stability
Low deformation
New design possibilities
Mechanical resistance equivalent to that of the base metal
Automotive
Laser welding of mechanical parts
The very low deformation due to the effect of the laser makes it possible to assemble finished parts such as components of gear boxes or cam shafts. Lasers also allow new assembly designs, for example to replace bolted assemblies in regulation components.
Advantages
Higher welding speed
Process stability
Low deformation
New design possibilities
Mechanical resistance equivalent to that of the base metal
IREPA LASER has leading-edge equipment dedicated to the laser welding of metals in order to handle the metal welding projects of its business customers.
Multi-mode fibre lasers up to 6 kW and single-mode up to 750 W, quasi continuous 600 W/6 kW
Pulsed YAG lasers
CO2 lasers up to 3.5 kW
Optical systems, focussing from 30 to 1000 µm diameter
Scan heads with path repositioning
Numerically controlled welding machine with 3 to 4 axes
Robot with positioner
Seam tracking
Beam analysis system
Metallurgy testing laboratory
Characterisation resources (NDT, chemical testing, mechanical testing, SEM, X-ray diffraction, salt spray, fatigue and vibration testing etc.)
The use of laser machines for welding metals provides an effective solution for many assembly needs (macro and micro). In order to secure optimum performance, in terms of both technology and costs, it is crucial to understand and control the operating parameters.
