Handheld Laser Welding Machine VS Traditional Welding

Welding is a critical process in metal parts manufacturing. It typically joins two separate metal parts. To do this, people use various methods. A Handheld laser welding machine and an arc welding machine are the most popular in the modern world. Many industries use this welding to produce parts, structures, and equipment.

The core part of this article discusses the suitability of different welding methods. Specifically, you will learn why handheld laser welding machines have replaced many traditional welding methods.

Understanding the Challenges of Welding Processes

Welding metal parts presents a few challenges. The most suitable method solves these challenges the most. The following are the most common challenges that you may often find when welding two metal parts.

Accuracy Problem

One of the biggest issues we often encounter in metal welding is accuracy. The alignment issue is the biggest problem, especially when dealing with machine parts. Welding must be accurate for some uses, like in automotive or aerospace. Inaccurate welds are indeed more prone to failure. Therefore, selecting the correct method is very important here.

Increased Heat and Control Issues

As you know, welding must produce high heat to melt metals for joining. However, when the metal reaches its melting point, it is challenging to control the welding process properly. Therefore, a skilled welder is always necessary, especially for traditional welding.

Heat affected zone

HAZ is a significant problem, especially when working with thin metals. It is also an excellent deal for low-melting point metals like aluminum and copper. A change in HAZ can affect some of the metal’s properties.

Material Compatibility

Not all welding processes work for every metal. Some metals, like aluminum, need special techniques; dissimilar metals are even harder to join.

Welding Thin or Delicate Materials

Thin materials are tricky to weld. They can burn through or bend if you give them too much heat. You must ensure that thin materials keep a straight edge, which may be problematic with certain processes.

Safety Concerns

When welding two things, you must be careful. The first is eye protection, and the other is the high-voltage electric shock. Therefore, safety is always a prime concern.

Can a Handheld Laser Welding Machine Meet These Challenges?

A handheld laser welding machine is one of the latest technologies of the twentieth century. People also call these machines portable welding machines. This method offers several advantages. These benefits typically make handheld laser welding machines ideal for a wide range of applications. This section proves whether a handheld laser welding machine can meet the abovementioned challenges.

Precision and Accuracy

A handheld laser welder uses a highly focused, tiny laser beam that hits the same place where you want to weld. It directs energy to the joint area, making clean and precise welds. It works great for jobs that need precision or close limits.

Heat Input and Control

Laser welding uses minimal heat. This heat is concentrated and controlled, reducing the material’s risk of damage. Because of this, a handheld laser welding machine or portable laser welder prevents warping or deformation.

Heat-Affected Zone (HAZ)

A handheld laser welding machine creates a small HAZ. You are already familiar with what HAZ is. You know it changes the properties of metals slightly. A handheld laser welder, in this case, keeps the material’s properties intact. The joint remains strong, and the material is less likely to become brittle.

Material Compatibility

Laser welding works with many materials. It can handle most grades of aluminum, stainless steel, and titanium. Since laser welding does not require filler welding, it is also effective for joining dissimilar metals.

Thermal Distortion

Laser welding focuses the laser beams directly at the places where you need the welding. As a result, it produces less heat-affected zone, resulting in minimal thermal distortion. In specific, the concentrated laser beam reduces bending or twisting. Because of this, handheld laser welding is ideal for thin or delicate metals.

Efficiency and Speed

If you want something efficient, handheld laser welding is the best. It is fast and accurate. Also, laser welding needs less filler compared to other traditional methods. They require fewer passes to complete a weld. As a result, laser welding ensures high productivity and less labor costs.

Can Traditional Welding Meet These Challenges?

In the previous section, you have seen how handheld laser welding meets the mentioned challenges. We will evaluate whether other traditional methods can deal with these problems. This way, you will understand why a handheld laser welding machine is ideal. Also, you will know the reasons why it replaces traditional welding methods.

Laser welding is a new technology, but people have depended on various traditional methods since the eighteenth century. These methods are still widely used today because they are cost-effective and available.

There are various traditional welding methods. Some common methods are MIG, TIG, and stick welding. These methods have been trusted for decades. Let’s check out whether they can meet the challenges of metal welding.

Heat Input

Traditional welding uses a high amount of heat. This can be good, and it works great for thicker materials. The heat melts the metal and creates a strong bond. Although it is suitable for thicker metals, it is not ideal for thin and low-melting-point metals. Excessive heat can cause many problems for them. It may weaken the surrounding metal or create a larger HAZ.

Precision

Traditional welding methods often struggle with precision and weld quality. A steady hand and good technique are always necessary. Conventional welding methods can give you good results only if you are a skilled and professional welder.

Thermal Distortion

High heat levels in traditional welding often lead to thermal distortion. This is especially true for thin materials. The metal expands during welding and contracts as it cools. Because of this, your metal parts can warp or bend. To fix it, you must add extra work, time, and cost.

Material Compatibility

Traditional welding works with many materials. You can easily do it on steel, aluminum, or even titanium. But it doesn’t always work for different metals or fragile things. It’s easy for thin metals to burn through. On the other hand, some metals need unique sets or methods, making traditional welding less useful in some situations.

Speed

Traditional welding usually takes a lot of time. Preparing the tools, setting up the materials, and finishing the weld takes time. A skilled welder might be able to do it faster, but still, the process is not faster than using a handheld laser welder.

Post-Weld Work

Traditional welding often requires extra steps after the weld is complete. You may need to clean, grind, or polish it. Most traditional welding methods produce a spatter, which you will later need to remove to smooth the surface.

Safety

Compared to handheld laser welding machines, traditional welding is prone to safety. The high heat and open flame can cause burns. Sparks and spatter may injure the welder or damage nearby objects. When you work with traditional welding, you must ensure proper protective equipment.

Flexibility

Traditional welding methods can be used for many jobs, so there is no question about it. But they might not be the best for delicate or complicated jobs. More modern methods, like small laser welding tools, work better in these situations.