Laser welding has revolutionized sheet metal fabrication and other processes, opening doors to crafting innovative products with impressive accuracies. It can also weld thick steel plates. But what is the limitation of steel laser welding thickness?
Laser welders can effectively join steel that is over 1-inch (25 millimeters) thick and some high-grade machines can handle even thicker steel plates. This capability means they’re suitable for both delicate electronic components and robust steel structures, showcasing their versatility in various applications.
We’ll discuss the capabilities of laser welders and the professional ways to do the welding. Keep reading and learn more about this fascinating technology.
How Thick Steel Can a Laser Welder Weld
Laser welding machines offer speed and precision, especially when working with steel plates. However, there are limits to steel laser welding thickness that you should know.
Laser Welder and Material Thickness
When using a laser with power up to 20 kW, it can penetrate steel about 1-mm for every kW of power. This means that a 20 kW laser could weld through approximately 20-mm of steel. But as the power increases beyond this point, the penetration rate changes. From 20 kW to 100 kW, the penetration drops to about 0.5-mm per kW. This shift is crucial for manufacturers to understand when selecting their equipment.
Many people believe that higher power lasers mean better results. While it’s true that more power can help with thicker materials, other factors also play significant roles. The overall quality of the machine, including its parts and the laser system, greatly influences the welding outcome. For example, a well-designed optical system can make a big difference in how effectively the laser works.
Choosing the right machine for steel laser welding involves more than just looking at the power. You should consider the machine’s accessories and overall design. A powerful laser that lacks quality components may not perform as expected. A high-quality setup can provide better welding results and more efficient production processes.
The Limit of Steel Laser Welding Thickness
How thick laser welding of steel can be mostly depends on the machine’s strength. For most standard setups, the maximum thickness is about 5 millimeters (or 0.2 inches), which works well for many projects.
When using a high-power laser, you can weld thicker plates. These powerful lasers can handle steel plates up to around 25 millimeters (1-inch) in one go. In some special cases, like with laser-arc hybrid welding techniques, you can even weld up to 50 millimeters (2 inches). This combination of methods allows for deeper and stronger welds.
It’s important to remember that not all materials are the same. The type of steel and its properties can change how well the laser works. For instance, welding carbon steel is different from welding 316L stainless steel (titanium steel). Each material requires its own settings to achieve the best results.
Laser Welders and Steel Welding Limits
Laser welders come in various power levels, such as 300W, 600W, and 1000W. Each level has its own strengths when it comes to steel laser welding thickness.
300W laser welders: The machine is best for thin materials. It can handle steel plates with surface thickness up to about 1.5-mm. If you’re working with something thicker, you might need to adjust the settings carefully. However, this isn’t always reliable, and welding thicker materials can be tricky.
600W laser welders: They’re great for welding kitchen appliances and other household items made from stainless steel. This machine can weld 1.5-mm steel plates that are less than 1-mm thick efficiently. It penetrates well, ensuring a strong joint.
1000W laser welders: They excel with steel up to 2-mm thick by creating precise welds. The speed of this welder is impressive, reaching over 1-meter per minute. If you’re looking for efficiency and quality, this is a solid choice.
1500W laser welders: the machine is ideal for 5-mm or thicker steel platers.
2000W laser welders: If you need to work with plates up to 8-mm thick, you’d want these welders. These machines are designed for more robust tasks and can provide the necessary power to ensure a strong weld.
If the weld needs to be larger than 0.3-mm, using a wire-feeding laser welder is recommended. This method helps achieve a thicker weld bead. However, for materials thinner than 1-mm, it’s better to avoid wire feeding. The welding speed without wire feeding is faster and more efficient for these thinner materials.
Zintilon can be your go-to option if you are looking for industry-standard laser weld service.
How to Laser Weld Steel Like a Pro
If you want to do laser welding of steel like a professional, you should have an idea about how this process works.
There are different types of laser machines, such as solid-state, fiber, and CO2 lasers. Each type has its own strengths, but they all create a strong light beam. This beam travels through a series of lenses that focus the light onto the metal parts that need to be joined.
When the focused beam hits the metal, it generates a lot of heat, which concentrates right at the spot where the two pieces meet. As the temperature rises, the metal begins to melt, forming a small pool of molten material. If needed, a filler rod can be added to this pool, which helps to strengthen the weld.
As the laser moves along the metal joint, it keeps melting the leading edge while the molten pool behind it starts to cool down and solidify. This creates a strong bond between the two pieces.
Now, let’s discuss the step-by-step procedure of how to laser weld steel:
Step 1: Prepare Your Materials
Before you start welding, take a moment to clean the steel parts. Dirt, grease, or rust can weaken the weld. Use a wire brush or a grinder to scrub the surfaces. It will ensure a strong welding bond.
Also, position the pieces correctly. Align them so there are no gaps between the edges.
Step 2: Secure Everything in Place
Once your materials are clean and aligned, it’s time to secure them. If the parts shift during welding, it can ruin your work. You can use manual clamps or even automated fixtures to keep everything steady. This way, the workpiece won’t move when the heat is applied.
Make sure everything is snug and secure before you start the welding process. A solid setup makes a huge difference in the quality of your weld.
Step 3: Focus the Beam
Adjusting the beam’s focal point is important for achieving a precise weld. Most welding torches come with optical equipment that makes this adjustment straightforward. You want the beam to hit the exact spot on your workpiece where you plan to weld. A well-focused beam ensures that the energy is concentrated, allowing for a clean and effective weld.
Step 4: Test the Power Settings
Once you’ve set the focus, it’s time to adjust the beam power. This step is about finding the perfect energy level for your specific material. You should always test on scrap pieces first to see how the laser interacts with the metal without risking your main workpiece.
Begin with a lower power setting and gradually increase it. The goal is to find enough energy to melt the steel without overheating it. Overheating can lead to warping or other damage. Pay close attention to how the scrap reacts. If it melts smoothly, you’re on the right track. If it starts to burn or create excessive spatter, dial back the power a bit.
Step 5: Apply the Beam
Now, it’s time to apply the beam at the eight spot of your workpiece. This first move is crucial. You want to create a melt pool that’s just right. Not too big, and not too small. Once you see that pool forming, it’s time to get moving.
As you guide the beam along the weld, keep a steady pace to keep the weld uniform. You can also try rotating the hot point slightly as you work. It’ll create a cleaner, higher-quality weld that lasts a long time.
Step 6: Let It Cool Down
After you’ve finished welding, don’t rush the cooling process. Allow the part to cool down naturally. This slow cooling can help minimize stress in the metal, making it less likely to warp or crack.
If you prefer a quicker method, you can dip the part in water. This technique can speed up the cooling, but it’s essential to be cautious. Rapid cooling can lead to unwanted changes in the metal’s properties.
Conclusion
Laser welding is a powerful tool that can create strong and precise welds in steel. While the steel laser welding thickness depends on factors like laser power and machine design, it’s clear that the technology offers versatility and efficiency across various industries. From delicate electronics to robust structures, the welding method is an important manufacturing process.
Need welding services for precision sheet metal fabrication for your project? Zintilon offers this along with laser cutting metal, custom CNC machining services and more. Contact us to discuss your requirements and get a quote.
