Laser welding is a process that uses a concentrated laser beam to fuse two pieces of metal. It has many advantages over other welding methods, such as arc welding. However, it also has some drawbacks.
Laser Welding Disadvantages
Specifically, we will go over 15 disadvantages of laser welding and identify any potential difficulties when dealing with this type of welding.
#1. High upfront cost.
Laser welding seems like a tailor-made solution for large and medium-scale industries. However, an automated laser welding system can cost you a fortune initially.
A regular laser welding setup can cost up to 3 times more than old-school welding setups. That’s why small businesses always feel reluctant to invest huge capital in one technology.
However, if you are considering a long-term investment, laser welding can lower your per-unit cost.
#2. Limited Penetration Depth.
Laser welding has a more limited depth of fusion capability than conventional welding. Some thicker materials require a high depth of fusion welding, which may not be possible with a laser welder.
Understand the specific requirements of the welding job before starting the welding job, evaluate and use the more appropriate welding method for the job.
#3. Sensitivity to Materials.
Laser welding can’t be used with as wide a range of materials as other types of welders. A laser welder could struggle with materials that are reflective and have high thermal conductivity (i.e., aluminum or copper alloys).
Laser welders don’t really like reflective surfaces because, during welding, a lot of the energy is reflected off the surface before it’s absorbed, and whatever is absorbed disperses quickly.
This makes it hard for the laser beam to properly heat the surface and create a strong enough weld.
When laser welding materials like high-carbon steel and aluminum alloys, the process’s rapid temperature change could cause them to crack, distort, and even change their material properties.
#4. Safety.
Laser welding can be a dangerous endeavor without sticking to all the safety precautions and careful and proper operation. If your skin comes in contact with the beam, it could cause serious injury and burns.
If you forget to wear protective eye goggles, eye trauma is a real possibility, and if you don’t work in a well-ventilated area, the gasses, vaporized particles, and fumes emitted from laser welding equipment could cause respiratory problems, among others.
To avoid injuries and health problems, make sure you have stocked up on (and wear) the appropriate safety gear, like goggles, face shields, and gloves.
You’ll also need to follow the correct safety procedures down to a T and weld in a ventilated area.
#5. Limited Joint Access.
Limited Joint Access can have a significant impact on laser welding. Since the laser beam can only reach a specific part of the joint, the size and shape of the part to be welded must be carefully considered.
This means that welding parts with complex geometries or difficult-to-access locations can present challenges.
Achieving full weld penetration may require multiple welds or part repositioning, which can further complicate and lengthen the welding process.
Essentially, limited access to the joint can hinder the simplicity and efficiency of laser welding, so it is necessary to overcome and overcome these potential obstacles to ensure a successful weld!
#6. Requires High Precision in Joint Preparation.
Laser welding demands very precise joint preparation and fit-up. Any gaps or misalignments can lead to defects in the weld.
This requirement for high precision can increase preparation time and costs, particularly for complex assemblies.
#7. Restricted Welding Positions.
Laser welding systems are generally less flexible in terms of welding positions.
While recent advancements have made it possible to weld at different angles and positions, the setups still lack the versatility offered by traditional welding techniques, which can be a limitation in complex welding operations.
#8. Reduced Weld Strength.
The downsides to laser welding include high cooling rates, partially completed fusion and penetration, material sensitivity, and joint design limitations, all of which could lead to weaker and less durable welds.
Weak welds are the last thing you’ll want as they can be a potential safety hazard leading to failures.
#9. Strict Supervision.
Laser welding gives results with precision and accuracy. Still, this precision can also become a curse if the settings of the welding machine are not adjusted accurately.
The automated laser welding setups have preset instructions, which must be applied carefully to avoid blunders in production.
Therefore, you need to make sure your production team actively follows the guidelines provided for high-quality manufacturing. You may have to hire expert technicians to monitor the welding process.
Now you know the advantages and disadvantages of laser welding over traditional welding methods. Now, what’s next? We will show you how you can find a reliable laser welding setup.
#10. Low backlash tolerance.
Low clearance tolerance means that the assembly accuracy of the weldment is high, and the position of the beam on the workpiece cannot have obvious deviations.
This is because the spot size of the focused laser is small and the weld seam is narrow, which is prone to welding defects when the workpiece is assembled or the beam positioning is inaccurate.
Low backlash tolerances mean you need to ensure that your upstream processes/suppliers can reliably meet tight tolerance levels.
#11. Training required.
In manufacturing and metal fabrication, laser welding has become a transformative technology, offering unparalleled precision and efficiency.
However, realizing the full potential of a laser welding machine requires more than purchasing equipment.
It requires extensive operator In modern training to ensure safe operation, optimize performance, and unlock the myriad benefits it offers. Operator training sessions can add to the overall cost of a laser welding machine.
#12. Limited application.
While a laser welding machine offers excellent advantages in many applications, it also has certain limitations, such as it is less suitable for welding thicker materials and cannot be used for certain types of joints.
Also, certain materials, such as highly reflective surfaces, may not be suitable for laser welding. In such cases, alternative welding methods such as arc welding or e-book welding may be more appropriate.
It is recommended that before a welding project begins, its specific requirements are assessed and an expert consulted to determine the most suitable welding method.
#13. Reduced Weldability in Certain Conditions.
Laser welding performance can be negatively impacted by environmental conditions such as lighting and dust. Any interference with the laser beam can affect the quality of the weld, making it less ideal in less controlled environments.
#14. Maintenance and Operational Costs.
The maintenance of laser welding equipment is complex and costly. Regular maintenance is crucial to ensure the equipment operates efficiently and safely.
Additionally, the operation of laser welding systems often requires consumables and occasional parts replacement, which can add to the ongoing costs.
#15. Limited Scalability and Flexibility.
Laser welding systems are designed for specific applications, which can limit their scalability and flexibility across different projects or production needs.
Adapting a laser welding setup for a new type of product or material often requires significant adjustments or additional equipment