Deep penetration laser welding is a non-contact joining process characterised by its high focused energy density, which is capable of producing high aspect ratio welds (weld width : weld depth) in many metallic materials. It can be performed at atmospheric pressure and with a relatively low heat input, compared with inert gas arc welding processes.
Deep penetration laser welding is a versatile fusion welding process, which has found wide application in industry; from spot welding of razor blades to welding of aerospace and marine structures. The process can be used to weld a variety of materials including, carbon steel, stainless steel, titanium, aluminium, nickel alloys. The industrial uptake of laser welding is driven by a requirement for high volume production and/or high weld quality.
The high focussability of laser beams enables power densities in the range 10^3 – 10^7 W/mm^2 to be applied to the joint. These power densities are sufficient to form a ‘keyhole’ (see video) below the laser beam impingement point. Efficient absorption of the laser beam by this keyhole allows low heat-input welds to be produced at fast processing speeds. These fast processing speeds combined with the ease of automation of industrial laser sources, lead to reliable, repeatable, and autonomous high volume production.
Heat inputs are ordinarily an order of magnitude lower than arc welding processes, promoting the adoption of deep penetration laser welding in components requiring minimal thermal distortion.
TWI has considerable experience in the successful development and qualification of deep penetration laser welding procedures for a variety of different applications, across numerous industry sectors.
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