Laser Welding Copper with the LightWELD XR

Laser welding is a precise and efficient welding technique that utilizes a high-energy laser beam to join metals together. When it comes to welding copper using laser technology, several key factors need to be considered due to copper's unique properties.

Here's how laser welding with the LightWELD XR of copper typically works:

1. Preparation: Before welding, the surfaces of the copper pieces to be joined must be thoroughly cleaned to remove any contaminants like oxides, grease, or dirt. This ensures proper fusion during welding. Additionally, the parts should be securely clamped or fixtured in place to maintain alignment during the welding process.

2. Laser Beam Generation: The LightWELD XR generates a highly concentrated beam of light, through the use of laser diodes. The laser beam is then directed towards the welding area using mirrors and lenses to focus the energy onto the copper surface.

3. Absorption of Laser Energy: Copper has relatively high reflectivity to laser light, especially at certain wavelengths. However, with the LightWELD XR, copper can absorb this laser energy efficiently. This energy absorption causes rapid heating of the copper surface.

4. Melting and Fusion: As the laser beam heats the copper surface, the material reaches its melting point, and localized melting occurs. The high energy density of the laser beam allows precise control over the depth of penetration and the size of the weld zone. As the molten material cools, it solidifies, forming a metallurgical bond between the copper pieces.

5. Control and Precision: The LightWELD XR offers exceptional control and precision, making it suitable for joining copper components without causing excessive heat distortion or damage. The focused nature of the laser beam enables welds with minimal heat-affected zones, resulting in high-quality and aesthetically pleasing joints.

6. Shielding Gas: To prevent oxidation and ensure the integrity of the weld, shielding gas is often used during laser welding of copper. Inert gases such as argon or helium are commonly employed to create a protective atmosphere around the weld zone, minimizing the risk of contamination and enhancing weld quality.

7. Automation and Integration: The LightWELD XR system can be integrated into a Fanuc CRX CoBot for high-volume manufacturing applications. The LightBOT systems enable precise control over the welding process, ensuring consistency and repeatability in production.

8. Post-Welding Inspection: After welding, the resulting welds should be inspected for defects such as cracks, porosity, or incomplete fusion. Non-destructive testing methods like visual inspection, dye penetrant testing, or X-ray inspection may be used to assess weld quality and integrity.

Overall, laser welding with the LightWELD XR offers numerous advantages for joining copper, including high precision, minimal heat input, and excellent control over the welding process. With proper setup and parameters, laser welding can produce strong and reliable welds in copper components for a wide range of applications across industries such as electronics, automotive, aerospace, and more.