Avoid These 5 Common Laser Welding Pitfalls
There’s no denying that new things are exciting. It can be tempting to dive right in and figure things out as you go along. But, while that might work when planning a vacation, it’s often better to slow down when it comes to a new industrial tool or process.
Handheld laser welding is no exception – in fact, it almost couldn’t be more applicable. Laser welding machines offer some seriously enticing advantages, but it’s important to remember that these tools represent one of the largest manual welding evolutions in the better part of a century.
Put another way, there’s no blueprint for success (although there are ways to increase your chances) and overeagerness has already left some fabricators feeling disappointed.
Whether for a one-off project or as part of serial production, if you want to enjoy the benefits of laser welding, understanding – and avoiding – these common pitfalls is absolutely essential.
#1. Writing off traditional welding experience
Overall, manual laser welding is not quite as difficult as traditional MIG or TIG welding. But a lot of the ease of use has to do with reduced manual dexterity requirements. When it comes to other welding skills, such as dialing in settings, prepping materials, and fixturing techniques, laser welding is roughly in line with arc welding.
What that means is that it’s risky to introduce laser welding to employees or teams with no welding experience. While powerful, these machines are not plug-and-play tools for total beginners.
On top of that, when and how to use laser welding is often better understood by experienced welders. Some of the key benefits of laser welding – like quality, consistency, and minimized heat input – can make it clear to them when old arc processes can be replaced.
The opposite is also true. Welders are typically better at wrapping their heads around some of laser welding’s challenges – like its limited ability to account for poor fit up – and, as a result, are more likely to pick the right tool for the job.
What you need to do
Try to make sure your initial users have MIG and/or TIG welding experience. They don’t necessarily have to be veterans or experts, but some arc welding experience makes it easier to hit the ground running with your new tool.
If that is not an option, be prepared to work through a little bit of a learning curve. Laser can be the first kind of welding a brand-new welder learns, but some trial and error will be necessary.
#2. Skipping training
Ask any fabricator having trouble integrating handheld laser welding into their operation and 3 out of 4 will say they should have opted for more training.
Some laser welding machine manufacturers offer free training in the form of videos covering the basics of lasers, safety, and equipment operation. More established brands also offer paid options, including virtual classes and in-person on-site sessions with laser welding experts where you can expect topics to focus more on your specific needs.
For equipment that is not supported by the manufacturer, your only option is consultation with a 3rd party laser welding specialist. While effective, this option is typically expensive and may not be tailored to your specific machine.
What you need to do
Before choosing a laser welder, reach out to manufacturers and ask them about their training options. Depending on what they offer, you may be able to schedule the desired training and even pay for it at the same time as your new equipment.
When it’s time to attend training sessions, involving key users and supervisors is a good idea. An experienced welding lead and a production supervisor are common choices, but other managers and even engineers can be good fits too.
#3. Ignoring laser safety
Safety is often top of mind in conversations around handheld laser welding. And that’s a good thing – high-power lasers are serious industrial equipment that must be understood and respected.
Fortunately, serious safety incidents like eye damage and severe burns appear to be extremely rare. However, minor issues like burnt fingers, combined with online misinformation, indicate that diligence and understanding are not yet at 100%.
What you need to do
Step one is to educate yourself. The good news is that many laser welding safety resources are freely available. While doing so, never forget the following basics.
Laser welding PPE is different. While gloves and attire are more or less interchangeable, laser welding helmets and laser safety glasses are not. Welders and observers must use materials and filters rated for sufficient protection against the specific wavelength of the laser welding machine.
Laser welding must be done in a controlled area. A Laser Controlled Area (LCA) refers to a space in which hazardous laser use is controlled and limited to trained personnel. In the case of laser welding, properly rated laser welding booths or curtains, or even a dedicated room, are usually sufficient.
Laser beams behave differently than welding arcs. Laser beams can travel hundreds of feet. Most laser welding machines will not fire without contact with the workpiece, but beams may pierce through material or reflect off the surface.
Once you have educated yourself, it is essential to involve all relevant users and employees. Facilities with laser welding equipment are legally obligated to designate a Laser Safety Officer who is responsible for enforcing and enabling a facility’s laser safety measures and educating its personnel.
#4. Expecting instant results
Laser welding is very powerful and can revolutionize everything from productivity to product design. But getting those kinds of results usually requires careful implementation.
Replacing a current process with laser welding may be messy if things like workflows, part tolerances, and joint configuration are not accounted for. Likewise, failing to document what’s working and what’s not make it that much harder to refine and scale appropriately.
What you need to do
The exact approach depends heavily on your industry, resources, and the sorts of things you are building. However, it’s generally a good idea to start off with a pilot program.
The best laser welding pilot programs focus on a few well-defined parts or the kinds of welds that are a good fit for laser welding. Measurable goals like reduction in weld time, improved appearance, or decreased post-weld grinding will reveal where results are lacking or, better yet, how laser welding can be utilized elsewhere.
You might find that you need to rethink your approach to clamping. Or you may discover that there’s an opportunity to completely redefine your fabrication process.
Either way, starting small and building upon what you’ve learned is important for long-term success.
#5. Misunderstanding maintenance requirements
Almost every industrial tool requires some kind of ongoing maintenance. With an arc welder, things like keeping nozzles, contact tips, and the interior clean and undamaged are routine. But many welders still have a limited understanding of the equivalent laser welder maintenance tasks.
A well-built laser welding machine lasts a long time and offers consistent performance day after day. All of that goes out the window if the machine is treated poorly and consumables are not regularly replaced.
When a machine is not performing as expected, the cause is almost always an easily avoidable routine maintenance issue.
What you need to do
Understanding is half the battle. First, familiarize yourself with your machine’s key parts and consumables. For a typical handheld laser welding machine, the list looks like this:
Cover lenses. Designed to protect more sensitive internal optics, these are your machine’s primary consumable and are easily accessible within the torch. Heavy use may mean replacing a cover lens every shift, with moderate use coming closer to 1 or 2 lenses a week. Failure to replace this inexpensive consumable will result in reduced weld penetration and can even damage your machine.
Focus lens. Under normal circumstances, the focus lens is a non-degrading component that rarely requires maintenance. But if the torch is opened to expose this lens to contamination or cover lenses are left unchanged for extended periods, this critical component may require servicing from the manufacturer.
Nozzle tips. Laser welding machines use a variety of nozzle tips to deliver shielding gas and, when applicable, filler wire to the weld joint. Nozzles are often optimized for different joint types such as lap, groove, fillet, or outside corners. Regardless of the type, these nozzles should be kept relatively clean and will require occasional replacement to achieve consistent results.
Welding torch and umbilical. Laser welding machines are industrial products designed to perform in rugged environments. However, it is still possible to damage critical components like the torch and the cord connecting it to the laser. Avoid slamming or dropping the torch or repeatedly wrenching the umbilical – otherwise your machine may require service.
Liquid cooling. For liquid-cooled machines, it is recommended to replace the water every few months to maintain the desired water level, ensure an ideal operating temperature, and prevent sediment build-up.
Once you understand what needs to be maintained, it’s a good idea to have a plan. At the bare minimum, ensure that there are always enough spare cover lenses and nozzle tips to prevent interruptions to day-to-day welding. The manufacturer of your machine should be able to provide advice on the best approach for you.
Some fabricators, especially those that have made laser welding a critical part of their process, keep more machines on hand than they strictly need. This prevents big disruptions in the event of unexpected downtime.