NEW Technology for Metal Welding !!!!

1. Conventional welding: TIG and MIG
Traditionally, MIG (Metal Inert Gas) Welding and TIG (Tungsten Inert Gas) Welding are the two most common welding forms. They work by using a shielding gas to create an inert atmosphere around the welding head. This inert atmosphere allows the welds to be isolated from other gases in the surrounding area which helps to stop the welds from becoming porous. An electric arc heats up the metal and metal filler, once melted it joins the material together to create a strong weld.

Metal Inert Gas (MIG) welding uses the heat generated by a DC electric arc to fuse the metal in the joint area. A continuous electrode (the wire) is fed by powered feed rolls (wire feeder) into the weld pool.

TIG welding uses a tungsten electrode to create the electrical arc and a handheld filler is used. Whereas in MIG welding the electrode also acts as a filler.

2. What is laser welding and how does it work?
Laser welding, or laser beam welding (LBW) is a highly efficient precision welding method that uses a high energy density laser beam as a heat source. The focused beam is directed to the surface of the part to be welded.

The laser welding process (mainly for sheet metal welding) can be divided into fiber continuous laser welding or YAG pulse laser welding according to the laser category.

The principle of laser welding can be divided into thermal conduction welding and deep penetration welding. The power density of less than 104~105 W/cm2 is for heat conduction welding. At this time, the penetration depth is shallow and the welding speed is slow. When the power density is greater than 105~107 W/cm2, the metal surface is concave into a “keyhole” under the action of heat to form deep fusion welding. The welding speed is fast and the aspect ratio is large.

The principle of thermal conduction laser welding is: laser radiation heats the metal surface to be processed, the surface heat is diffused to the inside through heat conduction, and the workpiece is melted by controlling the laser parameters such as the width, energy, peak power and repetition frequency of the laser pulse to form a specific molten pool. It is suitable for the welding of thin plates.

The deep penetration welding generally uses a fiber-optic continuous laser beam to complete the material welding. The laser beam not only melts the metal but also produces vapor. The dissipating vapor exerts pressure on the molten metal and partially displaces it. The material, meanwhile, continues to melt. The result is a deep, narrow, vapor-filled hole, or keyhole, which is surrounded by molten metal. As the laser beam advances along the weld joint, the keyhole moves with it through the workpiece. The molten metal flows around the keyhole and solidifies in its trail. This produces a deep, narrow weld with a uniform internal structure. The weld depth may be up to ten times greater than the weld width.

3. Advantages of laser welding over conventional welding
Easy operation-Laser welders don’t require great dexterity and skill that conventional welding does. Laser welding works from computer input whereas conventional welding requires somebody to operate the machine.

Higher weld strength– The weld strength is truly better than TIG and MIG Welding as the laser weld is narrow and has an excellent depth-width ratio.

Nearly no distortion- The heated area of the weld doesn’t spread to the rest of the material; thus, no concerns for weld weaknesses due to minimal distortion. It won’t cause distortion and change in the structure of the metal which can result in weaknesses in welds as the use of inert gas will do; and due to rapid cooling, the material can be handled almost instantly after the job is complete.

Aesthetically better weld finishes-More suited to high-value items such as jewelry. Ideal for solenoids and machined components, perfect for medical devices where weld quality is vital for hygiene and precision

Great accessibility-laser welder can weld from any angle of the workpiece, unlike the conventional method which is impossible to use in vertical or overhead positions due to liquidity of the weld

High Precision- Laser welding offers a much more precise weld in comparison to TIG and MIG welding. With 0.025mm precision you will find it hard to match a weld as precise as that.

4. Application of laser welding
Laser welding can be used to weld a whole array of metals such as carbon steel, high strength steel, stainless steel, titanium, aluminum, and precious metals. The laser welding machine is widely used in various industries:

Sanitary industry: welding of water pipe joints, reducers, tees, valves and showers.

Glasses industry: precision welding of glasses, such as stainless steel and titanium alloy, and the outer frame.

Hardware industry: impeller, kettle, handle, etc., welding of insulated cups, complex stamping parts and castings.

Automotive industry: engine cylinder head gasket, hydraulic tappet seal welding, spark plug welding, filter welding, etc.

Medical industry: welding of medical instruments, medical equipment, stainless steel seals, structural parts.

Electronics industry: solid-state relay seal welding, welding of connector connectors, welding of metal casings and structural parts such as mobile phones and MP3s. Welding of motor housings and wires, fiber optic connector connectors, etc.

As well as household hardware, kitchen utensils, stainless steel door handles, electronic components, sensors, watches, precision machinery, communications, handicrafts, automotive hydraulic tappets, and other high-intensity industry products welding.
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