3D Laser Welding: An Overview

Welding is a very complicated process in which weld quality can be affected by many parameters. To detect the presence of various weld defects and weld quality, many methods and systems have been studied and developed. 3D laser welding improves the efficiency and quality of welded projects over traditional welding methods like metal inert gas (MIG), metal active gas (MAG), and tungsten inert gas (TIG). Further, 3D welding is safer and more aesthetically pleasing than conventional welding methods. Its application in architecture and general building construction is beneficial and a recommended method for architects to employ in their current projects. In comparison to usual welding processes, welding is done with a 3D laser. Welding is especially neat and distortion is considerably reduced.

Traditional welding methods Vs 3D laser welding methods

The traditional welding (TIG and MIG) processes use a shielding gas to create an inert atmosphere around the welding head. In these processes, an arc is created by a tungsten electrode and a handheld filler material. In MIG welding electrode is the filler wire.

Spot welding is another frequently used welding method that works by clamping a pair of electrodes and electric current. These traditional welding processes transfer a significant amount of heat to the workpiece.

Meanwhile, in case of Laser welding, the heat is supplied by a highly focused light beam, diameter as small as 2000’s of an inch. The welding is conducted by firing a series of short pulses that melt the metal to create a very high-quality weld, as the heat input is minimized so parts can be handled almost immediately.

3D laser welding is one of the most widely known welding processes due to its accuracy. It is a high power density welding process used to join material pieces using energy emanating from a laser beam. The characteristics that set 3D laser welded products so special is deep weld penetration and minimized heat inputs.

Conventional welding practices are less efficient as the welder must frequently remove slag and change welding electrodes during the project. By using traditional welding practices, it takes approximately four minutes to weld ten inches; then, the welder spends relatively three minutes to grind the ten inches welded segment. In contrast, using 3D laser technologies, 160 inches can be welded in just over six seconds; using this technology requires no grinding or sanding, saving the project time and costs. 3D welding can reduce welding expenses roughly 84% as it can be up to 40x faster than conventional welding.

Using 3D laser technologies translates to higher quality results than traditional welding methods. Heat-affected zones created by 3D welding are significantly smaller than conventional welding. Reducing heat-affected zones helps to eradicate weakness and residual warping in the final product, which decreases safety concerns about the stability of weld bonds. Using 3D welds eliminates concerns about dross and porosity, which are common quality problems associated with traditional welding techniques.

Worker safety and health concerns are also mitigated by using 3D laser welding. Using traditional welding methods, workers are exposed to high heat, flames, and cornea damage or retina burning from prolonged exposure to ultraviolet light. In contrast, 3D welding technologies use a fiber laser welding machine, remotely monitored by a technician, and do not expose workers to dangerous, unhealthy conditions. Reducing workplace injuries and accidents allows projects to continue on-time and without unnecessary medical expenses.

Advantages of 3D laser welding

Due to its narrowness, a 3D laser weld has high weld strength with an excellent depth to width ratio and higher strength. Due to its rapid cooling of the heat, the affected zone is limited.

A 3D laser welding successfully welds dissimilar materials like aluminum, titanium, stainless steel carbon steel, etc.

A laser welded parts have a minimum deformity or shrink. Due to its lightly controlled beam, it permits accurate welding of micro and miniature components.

A 3D laser welding is easily controllable and generates very low volumes of scrap. Due to its controllability and negligible heating effects, it is very useful for welding high valued jewelry and other precious metals. Also due to it’s no welding splatter, it ensures hygiene which is tremendously effective for welding medical devices. Its non-contact laser beams permit welding in inaccessible areas.

Finally, 3D welds are more aesthetically pleasing than welds created by conventional methods. 3D weld bonds appear seamless, as though the stainless steel was bent into its shape. In comparison, finished traditional welds, like MIG, appear grainy, rough, and weak. Client satisfaction is likely to improve when finished products not only look better but also appear safer.

Final takeaway

A 3D laser welding is a highly productive method; there is no need for filler material to be used. The 3D laser provides a high quality weld and clean processing. That is the reason why most manufacturers, particularly in the automotive industries, aerospace, aircraft manufacturers, heavy vehicles jewelry manufacturing, medical industries, and in many other complex sectors, prefer it.

A 3d laser welding can solve much complicated engineering problems without an ease, especially while welding complicated components that are sensitive to excessive heat, or that require extremely non contact welding. 3D laser welding use in current architecture and construction projects will be more cost saving, efficient, safer, aesthetically pleasing, and produce higher quality products than if the same project used traditional welding techniques. As a result, customer satisfaction will increase and create more business opportunities.

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